2003 DODGE RAM Service Repair Manual

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Page 2497 of 2895

DODGE RAM 2003 Service Repair Manual TRANSFER CASE - NV243
TABLE OF CONTENTS
page page
TRANSFER CASE - NV243
DESCRIPTION........................658
OPERATION..........................659
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV243.....

TRANSFER CASE - NV243
TABLE OF CONTENTS
page page
TRANSFER CASE - NV243
DESCRIPTION........................658
OPERATION..........................659
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV243.......................659
REMOVAL............................660
DISASSEMBLY........................660
CLEANING...........................668
INSPECTION.........................668
ASSEMBLY...........................670
INSTALLATION........................679
SPECIFICATIONS
TRANSFER CASE - NV243.............680
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243........680
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL............................682
INSTALLATION........................682FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL............................682
FRONT OUTPUT SHAFT SEAL
REMOVAL............................683
INSTALLATION........................683
MODE SENSOR
DESCRIPTION........................684
OPERATION..........................684
SELECTOR SWITCH
DESCRIPTION........................685
OPERATION..........................685
SHIFT MOTOR
DESCRIPTION........................686
OPERATION..........................686
REMOVAL............................686
INSTALLATION........................686
TRANSFER CASE - NV243
DESCRIPTION
The NV243 is an electronically controlled part-time
transfer case with a low range gear reduction system.
The NV243 has three operating ranges plus a NEU-
TRAL position. The low range system provides a gear
reduction ratio for increased low speed torque capa-
bility.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
OPERATING RANGES
Transfer case operating ranges are:
²2WD (2-wheel drive)
²4HI (4-wheel drive)
²4LO (4-wheel drive low range)
²NEUTRAL
The 2WD range is for use on any road surface at
any time.The 4HI and 4LO ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a dash
mounted shift selector switch. The shift selector
switch provides a input to the Transfer Case Control
Module (TCCM) to indicate the driver's desire to
change operating ranges. The TCCM uses this input,
along with input from the transfer case mounted
mode sensor and information from the vehicle's bus,
to determine if a shift is permitted. If the TCCM
decides the shift is permitted, the TCCM controls the
shift motor, mounted to the exterior of the transfer
case, to perform the shift.
21 - 658 TRANSFER CASE - NV243DR

Page 2498 of 2895

DODGE RAM 2003 Service Repair Manual IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
T

IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range sleeve.
The front output shaft is operated by a drive chain
that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is engaged/disengaged
by the mode fork, which operates the mode sleeve
and hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV243
DIAGNOSIS CHART
Condition Possible Cause Correction
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case electronically
controlled shift system malfunction.1) Verify proper operation per the
appropriate diagnostic manual.
2) If vehicle was operated for an
extended period in 4HI mode on
dry surface, driveline torque load
may cause difficulty.2) Drive the vehicle in a straight line
and momentarily release the
accelerator. The transfer case can
then be shifted to the desired mode.
3) Insufficient or incorrect lubricant. 3) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, Automatic Transmission Fluid.
4) Internal transfer case
components binding, worn, or
damaged.4) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct quantity of MoparTAT F
+4, type 9602, Automatic
Transmission Fluid.
2) Internal transfer case
components binding, worn, or
damaged.2) Repair or replace components as
necessary.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
DRTRANSFER CASE - NV243 21 - 659
TRANSFER CASE - NV243 (Continued)

Page 2499 of 2895

DODGE RAM 2003 Service Repair Manual Condition Possible Cause Correction
Transfer case noisy while in, or
jumps out of, 4LO mode.1) Transfer case not completely
engaged in 4LO position.1) While rolling 2-3 MPH and the
transmission in NEU

Page 2500 of 2895

DODGE RAM 2003 Service Repair Manual SHIFT MOTOR ASSEMBLY AND FRONT OUTPUT
SHAFT SEAL
(1)Remove the bolts (Fig. 3) which hold the shift
motor and mode sensor assembly to the transfer case.
(2) Remove the shift motor and mode sensor
assem

Page 2501 of 2895

DODGE RAM 2003 Service Repair Manual (7) Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
(1) Remove rear extension bolts (Fig. 8).
(2) Remove rear extension housing (Fig. 9). Tap
extension once or twi

Page 2502 of 2895

DODGE RAM 2003 Service Repair Manual (2) Loosen rear case with pry tool to break sealer
bead. Insert tool in slot at each end of case (Fig. 12).
(3) Unseat rear case from alignment dowels.
(4) Remove rear case and oil pump assembly from

Page 2503 of 2895

DODGE RAM 2003 Service Repair Manual (3) Pull mainshaft, front sprocket and chain out-
ward about 25.4 mm (1-inch) simultaneously (Fig.
16).
(4) Remove chain from mainshaft drive sprocket
and remove front sprocket and chain as assembly.

Page 2504 of 2895

DODGE RAM 2003 Service Repair Manual (5) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 20).
(6) Remove mode fork, mode sleeve, and shift rail
as assembly (Fig. 21). Note which way the sleeve fits
in the fork (lon

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