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10. Install spring (2) onto shift rail (1).
11. Insert magnet (1) in front case pocket (2).
REAR CASE
1. Install the oil pick-up tube and screen into the rear
case half.
2. Apply bead of Mopar
Gasket Maker, or equivalent,
to mating surface of front case. Keep sealer bead
width to maximum of 3/16 inch. Do not use exces-
sive amount of sealer as excess will be displaced
into case interior.
3. Align mainshaft with he rear output shaft bearing
and align shift rail with bore in rear case. Then
install rear case (2). Verify that the case alignment
dowels correctly seat into their mating recesses.
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4. Install 4-5 rear case (2) -to- front case (1) bolts (3)
to hold rear case in position. Tighten bolts snug but
not to specified torque at this time.
CAUTION: Verify that shift rail, and case alignment
dowels are seated before installing any bolts.
Case could be cracked if shaft rail or dowels are
misaligned.
5. Tighten bolts to 27-34 Nꞏm (20-25 ft. lbs.),
6. Install rear output bearing inner snap-ring (3) to
output shaft (1).
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OIL PUMP AND REAR EXTENSION
1. Install the oil pump (3) onto the output shaft (2).
2. Engage the oil pump pick-up tube (2) into the oil
pump (1). Verify that the pick-up tube o-ring is on
the tube and is correctly installed to the oil pump.
Page 4164 of 5267
3. Apply bead of MoparGasket Maker, or equivalent,
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.
4. Install extension housing (2) onto the rear case half
(1).
5. Install rear extension bolts (2). Tighten the bolts to
27-34 Nꞏm (20-25 ft.lbs.).
Page 4165 of 5267

6. Install the extension housing boot and seal assem-
bly with Seal Installer 9037 (3) and Universal Han-
dle C-4171 (2).
7. Install the front companion flange onto the front
output shaft.
8. Install two bolts 180° apart into the front output
shaft companion flange.
9. Place holder (1) over the bolts (2) and against the
companion flange.
10. Install a new front companion flange nut. Tighten
the companion flange nut to 176-271 Nꞏm
(130-200 ft.lbs.).
INSTALLATION
1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with trans-
mission output shaft. Align splines by rotating transfer case rear outputshaft yoke if necessary. Do not install any
transfer case attaching nuts until the transfer case is completely seatedagainst the transmission.
2. Install and tighten transfer case attaching nuts. Tighten nuts to 30-41Nꞏm (20-30 ft.lbs.).
3. Remove jack stand from under transmission.
4. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER 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 transmission fluid and install fillplug.
Page 4166 of 5267
9. Install skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE -
INSTALLATION)
10. Lower vehicle
SPECIFICATIONS
TRANSFER CASE - NV271
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-25 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Nut, Range Lever 27-34 20-25 -
Sector Support 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Position Sensor 20-34 15-25 -
Nut, Companion Flange 176-271 130-200 -
Page 4167 of 5267
SPECIAL TOOLS
TRANSFER CASE NV271/NV273
Handle, Universal - C-4171
Remover - L-4454
Installer, Bearing - 6953
Installer, Pump Housing Seal - 7888
Installer, Bearing - 8128
Cup - 8148
Installer - 8151
Installer - 8152
Installer - 8891
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Socket - 9033
Installer, Bearing - 9035
Installer, Seal - 9036
Installer, Seal - 9037