2003 DODGE RAM Service Repair Manual

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Page 2505 of 2895

DODGE RAM 2003 Service Repair Manual MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
25) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
26) from the output shaft.
(3) Remove drive sprocket (Fig. 27)

Page 2506 of 2895

DODGE RAM 2003 Service Repair Manual (5) Remove the mode hub retaining ring (Fig. 30)
from the output shaft.
(6) Remove the mode hub (Fig. 31) from the output
shaft.INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw

Page 2507 of 2895

DODGE RAM 2003 Service Repair Manual INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 34).
(2) Remove retainer (Fig. 35).
(3) Remove front tabbed thrust washer (Fig. 36).
(4) Remove input gear

Page 2508 of 2895

DODGE RAM 2003 Service Repair Manual Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both th

Page 2509 of 2895

DODGE RAM 2003 Service Repair Manual Inspect the shift fork wear pads (Fig. 41). The
mode and range fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teet

Inspect the shift fork wear pads (Fig. 41). The
mode and range fork pads are serviceable and can be
replaced if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR EXTENSION HOUSING
Inspect the extension housing seal and bushing.
Replace both components if either show any sign of
wear or damage.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320-400 grit emery to
smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 42)
FRONT AND REAR CASES
Inspect the cases for wear and damage.Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoiltstain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 43) from
the front case with suitable snap-ring pliers.
(2) Transfer the retaining ring to the new bearing
if necessary and install the bearing into the front
case.
(3) Using Installer 6436 and Handle C-4171 (Fig.
44), remove front output shaft bearing.
(4) Start front output shaft bearing in case. Then
seat bearing with Handle C-4171 and Installer 6953.
(5) Install front output shaft bearing retaining
ring.
Fig. 41 Shift Fork And Wear Pad Locations
1 - RANGE FORK
2 - MODE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
Fig. 42 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 670 TRANSFER CASE - NV243DR
TRANSFER CASE - NV243 (Continued)

Page 2510 of 2895

DODGE RAM 2003 Service Repair Manual (6) Remove input gear pilot bearing by inserting a
suitably sized drift into the splined end of the input
gear and driving the bearing out with the drift and a
hammer (Fig. 45).
(7) Install new pilot

Page 2511 of 2895

DODGE RAM 2003 Service Repair Manual (9) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 47). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 48)

Page 2512 of 2895

DODGE RAM 2003 Service Repair Manual INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 51)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear
(Fig. 51). Be sure washer tabs are prop

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