Page 4297 of 5267
4. Insert front drive sprocket (3) in drive chain (2).
5. Install drive chain around rear drive sprocket.
6. Position rear drive sprocket over the output shaft
and lower the sprocket and chain assembly until
the front sprocket is positioned over the front out-
put shaft.
7. Align the splines in the sprockets to the splines on
the output shafts and install the sprockets onto the
output shafts.
8. Install front sprocket (2) retaining ring (3).
9. Install rear sprocket (2) retaining ring (3).
Page 4298 of 5267
10. 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 the 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.
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.).
Page 4299 of 5267
6. Install rear output bearing inner snap-ring (3) to
output shaft (1).
OIL PUMP AND REAR EXTENSION
1. Install the oil pump (3) onto the output shaft (2).
Page 4300 of 5267
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.
3. Apply bead of Mopar
Gasket 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 4301 of 5267

6. Install the extension housing dust boot and seal
assembly with Seal Installer 9037 (3) and Universal
Handle 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. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case onto the transmission.
5. Install and tighten transfer case attaching nuts to 27-34 Nꞏm (20-25 ft.lbs.) torque.
6. Connect the vent hose.
7. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.
8. Align and connect the propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/FRONT
PROPELLER SHAFT - INSTALLATION) (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/REAR
PROPELLER SHAFT - INSTALLATION)
9. Fill transfer case with correct fluid. (Refer to 21 - TRANSMISSION/TRANSFER CASE/FLUID - STANDARD PRO-
CEDURE)
10. Install skid plate, if equipped.
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11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.
SPECIFICATIONS
TRANSFER CASE - NV273
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Extension Housing 27-34 20-25 -
Bolt, Case Half 27-34 20-25 -
Support, Sector 27-34 20-25 -
Nuts, Mounting 30-41 20-30 -
Bolts, Shift Motor and
Mode Sensor Assembly16-25 12-18 -
Nut, Companion Flange 176-271 130-200 -
Page 4303 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