2003 DODGE RAM Service Repair Manual

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Page 2449 of 2895

DODGE RAM 2003 Service Repair Manual (14) Install mode fork and shift rail onto the mode
sleeve.
(15) Install the mode fork, sleeve, and shift rail
into the transfer case (Fig. 65).
(16) Install mainshaft into the transfer case (Fig.
66)

Page 2450 of 2895

DODGE RAM 2003 Service Repair Manual (20) Install new o-ring on detent plug (Fig. 69).
(21) Install detent plunger, spring, and plug (Fig.
70). Tighten the plug to 16-25 N´m (12-18 ft. lbs.).FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Instal

Page 2451 of 2895

DODGE RAM 2003 Service Repair Manual (4) Insert front sprocket in drive chain.
(5) Install drive chain around mainshaft sprocket
(Fig. 73). Then position front sprocket over front
shaft.
(6) Raise mainshaft about 2.54 cm (one inch) and
s

Page 2452 of 2895

DODGE RAM 2003 Service Repair Manual (2) Align oil pump with mainshaft and align shift
rail with bore in rear case. Then install rear case and
oil pump assembly (Fig. 77).
(3) Install 4-5 rear case-to front case bolts (Fig. 78)
to hold r

Page 2453 of 2895

DODGE RAM 2003 Service Repair Manual REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension h

REAR EXTENSION
(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(3) Align and install rear extension on retainer
(Fig. 80).
(4) Apply MopartSilicone Sealer to threads of rear
extension housing bolts. Then install and tighten
bolts to 16-24 N´m (12-18 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Remove jack stand from under transmission.
(4) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(5) Connect vent hose and transfer case position
sensor connector.
(6) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(7) Adjust shift linkage, if necessary.
(8) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(9) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(10) Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 40-45 30-40 -
Bolt, Extension Housing 16-24 12-18 -
Bolt, Case Half 20-27 15-24 -
Screw, Oil Pump 12-16 8-12 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-42 20-30 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 16-25 -
Fig. 80 Install Rear Extension Bolts
1 - EXTENSION HOUSING
2 - TRANSFER CASE
21 - 614 TRANSFER CASE - NV241 GENIIDR
TRANSFER CASE - NV241 GENII (Continued)

Page 2454 of 2895

DODGE RAM 2003 Service Repair Manual SPECIAL TOOLS
TRANSFER CASE - NV241/NV243
Handle, Universal - C-4171
Installer, Seal - 6888
Installer, Bearing - 6953
Installer, Seal - C-4210
Remover, Bushing - 6957
Installer, Bushing - 8157
Install

Page 2455 of 2895

DODGE RAM 2003 Service Repair Manual EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Usin

Page 2456 of 2895

DODGE RAM 2003 Service Repair Manual FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 82).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill

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