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(7) Using a screw and a slide hammer, remove the
front output shaft seal.
REAR EXTENSION
(1) Remove rear extension bolts (Fig. 8).
1 - EXTENSION HOUSING 2 - TRANSFER CASE 3 - PRY SLOT
(3) Remove output bearing retaining ring with
heavy duty snap-ring pliers (Fig. 10).
Fig.8RemoveRearExtensionBolts
1 - EXTENSION HOUSING 2 - TRANSFER CASE
Fig.10RemoveOutputShaftRetainingRing
1 - REAR OUTPUT SHAFT 2 - OUTPUT SHAFT BEARING 3 - RETAINING RING 4 - TRANSFER CASE
TRANSFER CASE - NV241 GENII
21 - 596
TRANSFER CASE - NV241 GENII (Continued) OIL PUMP AND REAR CASE(1) Remove rear case-to-front case bolts (Fig. 11).
Fig.11RemoveCaseBolts
1 - REAR CASE 2 - FRONT CASE 3 - BOLT
(2) Loosen rear case with pry tool to break sealer bead. Insert tool in slot at each end of case (Fig. 12).
Fig.12LoosenCaseHalves
1 - REAR CASE 2 - FRONT CASE 3 - PRY SLOTS
DR
(3) Unseat rear case from alignment dowels. (4) Remove rear case and oil pump assembly from
front case (Fig. 13).
CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft bearing inner race and will become mis-aligned if the bolts are loosened. If the transfer case failure has gener- ated any debris which may have become trapped in the oil pump, the rear case and oil pump assembly MUST be replaced.
Fig.13RemoveRearCase
1 - REAR CASE 2 - FRONT CASE
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove shift rail cup and spring (Fig. 14).
Fig.14ShiftRailCupAndSpringRemoval
1 - SHIFT RAIL 2 - SPRING 3 - CUP
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 597
(2) Remove front sprocket retaining ring (Fig. 15).
SHIFT FORKS AND MAINSHAFT
(1) Remove the transfer case position sensor (Fig.
17).
Fig.15RemovingFrontSprocketRetainingRing 1 - FRONT SPROCKET 2 - RETAINING RING 3 - FRONT OUTPUT SHAFT
(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.
Fig.17RemovePositionSensor
1 - FRONT CASE 2 - POSITION SENSOR
(2) Loosen detent plug. (3) Remove detent plug, spring, and plunger (Fig. 18). Note that the plug has an O-ring seal. Remove and discard this seal.
Fig.16RemoveFrontSprocketandDriveChain
1 - FRONT DRIVE SPROCKET 2 - DRIVE CHAIN 3 - MAINSHAFT
Fig.18RemoveDetentPlug,Spring,andPlunger 1 - FRONT CASE 2 - DETENT PLUG 3 - DETENT SPRING 4 - DETENT PLUNGER
21 - 598
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
(4) Remove the front output shaft snap-ring (Fig.
19).
(6) Pull mainshaft assembly out of
mode sleeve, and case (Fig. 21).
input gear,
Fig.19RemoveFrontOutputShaftSnap-ring
Fig.21RemoveMainshaft
1 - FRONT OUTPUT SHAFT 2 - SNAP-RING
1 - FRONT CASE 2 - MAINSHAFT
(5) Remove front output shaft from bearing in case
(Fig. 20).
(7) Remove mode fork, mode sleeve, and shift rail as assembly (Fig. 22). Note which way the sleeve fits in the fork (long side of sleeve goes to front).
Fig.20RemoveFrontOutputShaft
1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
Fig.22RemoveModeForkandShiftRail
1 - MODE FORK 2 - SHIFT RAIL 3 - MODE SLEEVE
DR TRANSFER CASE - NV241 GENII (Continued)
(8) Remove range fork retaining ring. (9) Remove range fork and hub as an assembly (Fig. 23). Note fork position for installation reference.
(10) Remove the shift sector support (Fig. 24). (11) Remove shift sector (Fig. 25).
TRANSFER CASE - NV241 GENII
21 - 599
Fig.25RemoveShiftSector
1 - SHIFT SECTOR
Fig.23RangeForkAndHubRemoval
1 - RANGE HUB 2 - RANGE FORK
Fig.24RemoveSectorSupport
1 - SECTOR SUPPORT 2 - FRONT CASE 3 - SECTOR SHAFT
MAINSHAFT
(1) Remove the drive sprocket retaining ring (Fig.
26) from the output shaft.
27) from the output shaft.
(2) Remove the drive sprocket thrust washer (Fig.
Fig.26RemoveTheDriveSprocketRetainingRing 1 - OUTPUT SHAFT 2 - RETAINING RING 3 - DRIVE SPROCKET
Fig.27RemoveDriveSprocketThrustWasher
1 - OUTPUT SHAFT 2 - THRUST WASHER 3 - DRIVE SPROCKET
21 - 600
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
(3) Remove drive sprocket (Fig. 28) from the out-
put shaft.
(4) Remove the clutch gear (Fig. 29) and hub (Fig.
30) from the output shaft.
Fig.30RemoveSprocketHub
1 - OUTPUT SHAFT 2 - SPROCKET HUB
Fig.28RemoveDriveSprocket
1 - OUTPUT SHAFT 2 - DRIVE SPROCKET
Fig.31RemoveRetainingRing
1 - OUTPUT SHAFT 2 - RETAINING RING 3 - MODE HUB
Fig.32RemoveModeHub
1 - OUTPUT SHAFT 2 - MODE HUB
Fig.29RemoveClutchGear
1 - OUTPUT SHAFT 2 - CLUTCH GEAR 3 - MODE HUB
(5) Remove the mode hub retaining ring (Fig. 31)
from the output shaft.
(6) Remove the mode hub (Fig. 32) from the output
shaft.
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.
(3) Place front case in horizontal position. Then remove input gear and low range gear as an assem-
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 601
INPUT AND PLANETARY GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 35).
(2) Remove retainer (Fig. 36).
Fig.33RemoveInputGearRetainingRing
1 - INPUT GEAR 2 - RETAINING RING
bly (Fig. 34). Tap gear out of bearing with plastic mallet, if necessary.
Fig.35InputGearSnap-RingRemoval
1 - INPUT GEAR SNAP-RING
Fig.34RemoveInputPlanetaryAssembly
1 - FRONT CASE 2 - INPUT PLANETARY ASSEMBLY
Fig.36InputGearRetainerRemoval
1 - INPUT GEAR 2 - LOW RANGE GEAR 3 - RETAINER
21 - 602
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
(3) Remove front tabbed thrust washer (Fig. 37). (4) Remove input gear (Fig. 38). (5) Remove rear tabbed thrust washer from low
range gear (Fig. 39).
DR
Fig.37FrontTabbedThrustWasherRemoval
1 - FRONT TABBED THRUST WASHER
Fig.39RearTabbedThrustWasherRemoval
1 - LOW RANGE GEAR 2 - REAR TABBED THRUST WASHER
INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone, however, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Fig.38InputGearRemoval
1 - INPUT GEAR 2 - LOW RANGE GEAR
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.
Check the teeth on the gear (Fig. 40). Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery cloth if necessary.
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 thrust washers for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift rail (Fig. 41). Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 42). The mode fork pads are serviceable and can be replaced if necessary. The range fork pads are not serviceable. The fork must be replaced as an assembly if the pads are worn or damaged.
Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 603
1 - PLANETARY CARRIER 2 - REAR THRUST WASHER 3 - FRONT THRUST WASHER
Fig.40InputGearAndCarrierComponents 4 - CARRIER LOCK RING 5 - CARRIER LOCK RETAINING RING 6 - INPUT GEAR
Fig.41ShiftForks
1 - RANGE FORK 2 - MODE FORK AND RAIL 3 - MODE SPRING
REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bear- ing if rough or noisy. Check the retainer for cracks or wear in the bearing bore.
Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.
Inspect rear extension bushing. Replace if worn or
scored.
Fig.42ShiftForkAndWearPadLocations
1 - RANGE FORK 2 - MODE FORK 3 - WEAR PADS (SERVICEABLE) 4 - WEAR PADS (SERVICEABLE)
DRIVE CHAIN
Examine the drive chain and shaft bearings. replace the chain if stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.
TRANSFER CASE - NV241 GENII
21 - 604
TRANSFER CASE - NV241 GENII (Continued) LOW RANGE ANNULUS GEARASSEMBLY
DR
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. 43)
Fig.43LowRangeAnnulusGear
1 - FRONT CASE 2 - LOW RANGE ANNULUS GEAR
FRONT CASE AND REAR CASE
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 Loctite™ 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 Helicoil™ stain- 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.
BEARINGS AND SEALS
(1) Remove the input shaft bearing (Fig. 44) 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.
Fig.44RemoveInputGearBearing
1 - INPUT GEAR BEARING 2 - FRONT CASE
(3) Using Installer 6436 and Handle C-4171 (Fig.
45), remove front output shaft bearing.
(4) Start front output shaft bearing in case. Then seat bearing with Handle C-4171 and Installer 6953.
Fig.45RemoveFrontOutputShaftBearing
1 - FRONT CASE 2 - INSTALLER 6436
3 - HANDLE C-4171DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 605
(5) Install
front output shaft bearing retaining
ring.
(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. 46).
(7) Install new pilot bearing with Remover/In-
staller 8684.
Fig.46RemoveInputGearCupPlug
1 - DRIFT 2 - INPUT GEAR
(8) Remove the front output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 47).
(9) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 48). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 49).Fig.47FrontOutputShaftRearBearingRemoval 1 - REAR CASE 2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148Fig.48OutputShaftRearBearingInstallation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING 3 - INSTALLER 506621 - 606
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
Fig.49OutputShaftRearBearingInstallationDepth 1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER 2 - CHAMFER
(10) Remove the rear output shaft bearing from the rear case using Remover/Installer 8684 and Han- dle C-4171 (Fig. 50).
(11) Install the rear output shaft bearing (Fig. 51) into the rear case using Remover/Installer 6953 and Handle C-4171.
Fig.50RemoveRearOutputShaftBearing
1 - REAR CASE 2 - REMOVER/INSTALLER 8684
3 - HANDLE C-4171INPUT AND PLANETARY GEAR
(1) Lubricate gears and thrust washers (Fig. 52)
with recommended transmission fluid.
(2) Install first thrust washer in low range gear (Fig. 52). Be sure washer tabs are properly aligned in gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
Fig.51InstallRearOutputShaftBearing
1 - REAR CASE 2 - REMOVER/INSTALLER 6953
3 - HANDLE C-4171(4) Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
Fig.52Input/LowRangeGearComponents
1 - SNAP-RING 2 - RETAINER PLATE 3 - INPUT GEAR 4 - LOW RANGE GEAR 5 - THRUST WASHERS
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 607
(6) Align and install low range/input gear assem- bly in front case (Fig. 53). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.
(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 54).
SHIFT FORKS AND MAINSHAFT
(1) Lubricate mainshaft splines with recommended
transmission fluid.
shaft.
(2) Install the mode hub (Fig. 55) onto the output
(3) Install the mode hub retaining ring (Fig. 56)
(8) Install a new input gear seal using Installer
onto the output shaft.
8841 and Handle C-4171.
Fig.53InstallInputPlanetaryAssembly
1 - FRONT CASE 2 - INPUT PLANETARY ASSEMBLY
Fig.55InstallModeHub
1 - OUTPUT SHAFT 2 - MODE HUB
Fig.54InstallInputGearRetainingRing
1 - INPUT GEAR 2 - RETAINING RING
Fig.56InstallModeHubRetainingRing
1 - OUTPUT SHAFT 2 - RETAINING RING 3 - MODE HUB
21 - 608
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
(4) Install the sprocket hub (Fig. 57) onto the out-
(5) Install the clutch gear (Fig. 58) onto the output
(6) Install the drive sprocket (Fig. 59) onto the out-
put shaft.
shaft.
put shaft.
Fig.59InstallDriveSprocket
1 - OUTPUT SHAFT 2 - DRIVE SPROCKET
(7) Install the drive sprocket thrust washer (Fig.
60) onto the output shaft.
Fig.57InstallSprocketHub
1 - OUTPUT SHAFT 2 - SPROCKET HUB
Fig.58InstallClutchGear
1 - OUTPUT SHAFT 2 - CLUTCH GEAR 3 - MODE HUB
Fig.60InstallDriveSprocketThrustWasher
1 - OUTPUT SHAFT 2 - THRUST WASHER 3 - DRIVE SPROCKET
DR TRANSFER CASE - NV241 GENII (Continued)
(8) Install the drive sprocket retaining ring (Fig.
61) onto the output shaft.
TRANSFER CASE - NV241 GENII
21 - 609
Fig.61InstallTheDriveSprocketRetainingRing 1 - OUTPUT SHAFT 2 - RETAINING RING 3 - DRIVE SPROCKET
(9) Lubricate sector shaft with transmission fluid and install shift sector in case (Fig. 62). Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.
(10) Install
the shift sector support
(Fig. 63). to 27-42 N·m (20-30
Tighten the sector support ft.lbs.).
Fig.63InstallSectorSupport
1 - SECTOR SUPPORT 2 - FRONT CASE 3 - SECTOR SHAFT
(11) Assemble and install range fork and hub (Fig. 64). Be sure hub is properly seated in low range gear and engaged to the input gear.
(12) Align and insert range fork pin in shift sector
slot.
(13) Install the range fork retaining ring.
Fig.62InstallShiftSector
1 - SHIFT SECTOR
Fig.64InstallRangeForkAndHubAssembly
1 - RANGE HUB 2 - RANGE FORK
21 - 610
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
(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).
(17) Install the transfer case position sensor (Fig. 67). Tighten the sensor to 20-34 N·m (16-25 ft. lbs.) torque.
Fig.65InstallModeForkandShiftRail
1 - MODE FORK 2 - SHIFT RAIL 3 - MODE SLEEVE
(16) Install mainshaft into the transfer case (Fig. 66). Guide mainshaft through the mode and range sleeves and into the input gear.
Fig.67InstallPositionSensor
1 - FRONT CASE 2 - POSITION SENSOR
(18) Install range lever on sector shaft (Fig. 68). (19) Install washer and nut on sector shaft to secure shift lever. Apply 1-2 drops Mopart Lock N’ Seal, or equivalent, to nut threads before installation. Then tighten nut to 27-34 N·m (20-25 ft. lbs.) torque.
Fig.66InstallMainshaft
1 - FRONT CASE 2 - MAINSHAFT
Fig.68InstallRangeLeverNut
1 - RANGE LEVER
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 611
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install the front output shaft (Fig. 71) into the
front output shaft bearing.
(2) Install the front output shaft retaining ring
(Fig. 72) onto the output shaft.
(3) Install the new front output shaft seal with
Installer MB991168A
(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.).
Fig.69O-RingInstallationOnDetentPlug
1 - O-RING 2 - DETENT PLUG
Fig.71InstallFrontOutputShaft
1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
Fig.70InstallDetentPlug,Spring,andPlunger
1 - FRONT CASE 2 - DETENT PLUG 3 - DETENT SPRING 4 - DETENT PLUNGER
Fig.72InstallFrontOutputShaftSnap-ring
1 - FRONT OUTPUT SHAFT 2 - SNAP-RING
21 - 612
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
(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
seat front sprocket on front output shaft.
Fig.73InstallFrontSprocketandDriveChain
1 - FRONT DRIVE SPROCKET 2 - DRIVE CHAIN 3 - MAINSHAFT
(7) If mainshaft and mode sleeve were unseated during chain installation, align and reseat mainshaft in input gear and hub.
(8) Install front sprocket retaining ring (Fig. 74).
Fig.74FrontSprocketRetainingRingInstallation 1 - FRONT SPROCKET 2 - RETAINING RING
(9) Install spring and cup on shift rail (Fig. 75).
Fig.75ShiftRailSpringAndCupInstallation
1 - CUP 2 - SPRING
(10) Insert magnet in front case pocket (Fig. 76).
Fig.76CaseMagnetInstallation
1 - MAGNET 2 - CASE POCKET
OIL PUMP AND REAR CASE
CAUTION: Do not remove the bolts holding the oil pump cover to the rear case half. The oil pump cover is aligned to the rear output shaft inner bear- ing race and will become mis-aligned if the bolts are loosened. If the transfer case failure has gener- ated any debris which may have become trapped in the oil pump. the rear case and oil pump assembly MUST be replaced.
(1) Apply bead of Mopart Gasket Maker, or equiv- alent, to mating surface of front case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
DR TRANSFER CASE - NV241 GENII (Continued)
(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).
TRANSFER CASE - NV241 GENII
21 - 613
Fig.78InstallCaseBolts
1 - REAR CASE 2 - FRONT CASE 3 - BOLT
Fig.77InstallRearCase
1 - REAR CASE 2 - FRONT CASE
(3) Install 4-5 rear case-to front case bolts (Fig. 78) 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 mis- aligned.
(4) Apply Loctite™ 242 to remainder of rear case- to-front case bolt threads and install bolts. Tighten bolts to 20-27 N·m (15-24 ft. lbs.),
(5) Install rear output bearing snap-ring (Fig. 79)
to output shaft.
SEAL BOOT
(1) Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
(2) Install a new seal boot clamp onto the seal
boot.
(3) Install the seal boot and clamp onto the slinger clamp with Crimp Tool
hub and tighten the C-4975-A.
Fig.79InstallOutputShaftRetainingRing
1 - REAR OUTPUT SHAFT 2 - OUTPUT SHAFT BEARING 3 - RETAINING RING 4 - TRANSFER CASE
TRANSFER CASE - NV241 GENII
21 - 614
TRANSFER CASE - NV241 GENII (Continued) REAR EXTENSION(1) Install new seal in rear extension housing seal
with Installer D-163 and Handle C-4171..
(2) Apply bead of Mopart Gasket 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).
DR
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 - DRIVELINE/PROPELLER
DIFFERENTIAL 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
Fig.80InstallRearExtensionBolts
1 - EXTENSION HOUSING 2 - TRANSFER CASE
(4) Apply Mopart Silicone Sealer to threads of rear extension housing bolts. Then install and tighten bolts to 16-24 N·m (12-18 ft. lbs.) torque.
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
TORQUE SPECIFICATIONS
DESCRIPTION
Plug, Detent Plug, Drain/Fill
Bolt, Extension Housing
Bolt, Case Half Screw, Oil Pump Nut, Range Lever
Sector Support Nuts, Mounting Position Sensor
N-m 16-24
40-45
16-24
20-27
12-16
27-34
27-42
30-41
20-34Ft. Lbs. 12-18
30-40
12-18
15-24
8-12
20-25
20-30
20-30
16-25In. Lbs.
DR TRANSFER CASE - NV241 GENII (Continued) SPECIAL TOOLS
TRANSFER CASE - NV241/NV243
TRANSFER CASE - NV241 GENII
21 - 615
Remover,Bushing-6957
Handle,Universal-C-4171
Installer,Bushing-8157
Installer,Seal-6888
Installer,Bearing-6953
Installer,Seal-C-4210
Installer,Seal-D-163
Installer,Seal-7884
Installer,Bushing-5066
21 - 616
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
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) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension housing with fluid port in bushing aligned with slot in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 81).
Plug,Extension-C-293-3
Remover-L-4454
Cup-8148
Installer,PumpHousingSeal-7888
Fig.81InstallRearSealinExtensionHousing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163(5) Install propeller shaft. (Refer to 3 - DIFFER- ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO- PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level. (7) Lower vehicle.
DR
TRANSFER CASE - NV241 GENII
21 - 617
FRONT OUTPUT SHAFT SEAL REMOVAL
(1) Remove the front propeller shaft (Refer to 3 - DRIVELINE/PROPELLER
DIFFERENTIAL SHAFT/PROPELLER SHAFT - REMOVAL).
(2) Remove the front propeller shaft seal boot
retaining clamp (Fig. 83).
(3) Remove the front propeller shaft seal boot (Fig.
84).
FLUID STANDARD PROCEDURE - FLUID DRAIN AND REFILL
The fill and drain plugs are both in the rear case
(Fig. 82).
Fig.82Fill/DrainPlugandI.D.TagLocation-
Typical
1 - I.D. TAG 2 - FILL PLUG 3 - DRAIN PLUG
(1) Raise vehicle. (2) Position drain pan under transfer case. (3) Remove drain and fill plugs and drain lubri-
(4) Install drain plug. Tighten plug to 41-54 N·m
cant completely.
(30-40 ft. lbs.).
(5) Remove drain pan. (6) Fill transfer case to bottom edge of fill plug opening with Mopart ATF +4, Automatic Transmis- sion fluid.
(7) Install and tighten fill plug to 41-54 N·m
(30-40 ft. lbs.).
(8) Lower vehicle.
Fig.83RemoveBootClamp
1 - SEAL BOOT 2 - BOOT CLAMP
Fig.84RemoveSealBoot
1 - SEAL BOOT 2 - SEAL SLINGER
21 - 618
FRONT OUTPUT SHAFT SEAL (Continued)TRANSFER CASE - NV241 GENII
(4) Remove the front output shaft seal slinger by bending (Fig. 85) the slinger ears away from the transfer case.
(5) Using a suitable pry tool (Fig. 86), remove the slinger from the output shaft using care not to dam- age the shaft.
DR
(6) Using a screw and a slide hammer, remove the
front output shaft seal.
INSTALLATION
(1) Install the new front output shaft seal with
Installer MB991168A
(2) Install the front output shaft seal slinger with Installer 8840. Install the slinger onto the shaft until the tool contacts the rear of the output shaft.
(3) Install a new seal boot clamp onto the seal
boot.
(4) Install the seal boot and clamp onto the slinger clamp with Crimp Tool
hub and tighten the C-4975-A.
(5) Install front propeller shaft (Refer to 3 - DIF- FERENTIAL & DRIVELINE/PROPELLER SHAFT/ PROPELLER SHAFT - INSTALLATION).
POSITION SENSOR DESCRIPTION
The transfer case position sensor is an electronic device whose output can be interpreted to indicate the transfer case’s current operating mode. The sen- sor consists of a five position, resistive multiplexed circuit which returns a specific resistance value to the Powertrain Control Module (PCM) for each trans- fer case operating mode. The sensor is located on the top of the transfer case, just left of the transfer case centerline and rides against the sector plate rooster- comb. The PCM supplies 5VDC (+/- 0.5V) to the sen- sor and monitors the return voltage to determine the sector plate, and therefore the transfer case, position.
Fig.85BendSlingerEars
1 - SLINGER 2 - BEND UPWARD
Fig.86RemoveSlingerFromShaft
1 - SLINGER 2 - PRY TOOL
DR POSITION SENSOR (Continued) OPERATION
During normal vehicle operation, the Powertrain Control Module (PCM) monitors the transfer case position sensor return voltage to determine the oper-
TRANSFER CASE - NV241 GENII
21 - 619
ating mode of the transfer case. Refer to the Operat- ing Mode Versus Resistance table for the correct resistance for each position (Fig. 87).
OPERATING MODE VERSUS RESISTANCE
SENSOR POSITION
OPERATING MODE
SENSOR RESISTANCE (ohms)
2H 4H
NEUTRAL
4L
NOT USED
REMOVAL
1124-1243
650-719
389-431
199-221
57-64(1) Raise and support the vehicle. (2) Disengage the transfer case position sensor
connector from the position sensor.
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into the transfer case. Torque the sensor to 20-34 N·m (15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle. (5) Verify proper sensor operation.
Fig.87PositionSensorLinearMovement
1 - POSITION 1 - 10mm ±0.5mm 2 - POSITION 2 - 12mm ±0.5mm 3 - POSITION 3 - 14mm ±0.5mm 4 - POSITION 4 - 16mm ±0.5mm 5 - POSITION 5 - 18mm ±0.5mm 6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION
21 - 620
TRANSFER CASE - NV241 GENII
DR
SHIFT LEVER REMOVAL
(1) Shift transfer case into 2H. (2) Raise and support the vehicle. (3) Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion. If rod lacks enough travel to come out of trunnion, push trunnion out of shift lever.
(4) Lower vehicle. (5) Remove transfer case shifter knob cap. (6) Remove nut holding shifter knob to shift lever. (7) Remove shifter knob. (8) Remove the shift boot from the shifter console. (9) Remove the bolts securing the shifter mecha-
nism to the floor pan (Fig. 88).
(10) Separate shift lever mechanism from the vehi-
cle.
1 - SHIFTER BOOT 2 - SHIFTER KNOB 3 - SHIFTER CONSOLE
Fig.88TransferCaseShifter
4 - SHIFTER MECHANISM 5 - ALIGNMENT PIN 6 - TRANSFER CASE
DR SHIFT LEVER (Continued) INSTALLATION
(1) If
the shifter mechanism does not have a adjustment locating pin installed, align the adjust- ment channel on the shifter assembly to the locating hole in the lower shift lever and install an appropri- ately sized pin to retain the position (Fig. 89).
(2) Position shift lever in vehicle. (3) Install the bolts to hold the shifter mechanism
to the floor pan.
(4) Raise vehicle. (5) Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the second position from full forward.
TRANSFER CASE - NV241 GENII
21 - 621
(6) Install trunnion to shift lever, if necessary. (7) Install shift rod to trunnion, if necessary. (8) Tighten the shift rod lock bolt to 10 N·m (90
in.lbs.).
(9) Remove the shifter adjustment locating pin from the adjustment channel and the locating hole.
(10) Lower vehicle. (11) Install the transfer case shifter console. (12) Install the shifter boot and the shifter knob
onto the shifter lever.
(13) Install nut to hold shifter knob to shift lever. (14) Install shifter knob cap. (15) Verify transfer case operation.
1 - SHIFTER BOOT 2 - SHIFTER KNOB 3 - SHIFTER CONSOLE
Fig.89TransferCaseShifter
4 - SHIFTER MECHANISM 5 - ALIGNMENT PIN 6 - TRANSFER CASE
TRANSFER CASE - NV241 GENII
21 - 622
SHIFT LEVER (Continued) ADJUSTMENTSADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position. (2) Raise vehicle. (3) Loosen shift rod lock bolt at trunnion. (4) Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if necessary.
(5) Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the trans- fer case shift arm is the second position from full for- ward.
DR
(6) Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket assembly (Fig. 90).
(7) Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the shifter in the correct position.
(8) Tighten shift rod lock bolt to 10 N·m (90 in.
lbs.) torque.
(9) Remove the locating pin from the adjustment
channel and locating hole.
(10) Check shift linkage operation. Be sure trans- fer case shifts into and operates properly in all ranges.
1 - SHIFTER BOOT 2 - SHIFTER KNOB 3 - SHIFTER CONSOLE
Fig.90TransferCaseShifter
4 - SHIFTER MECHANISM 5 - ALIGNMENT PIN 6 - TRANSFER CASE
DR
TRANSFER CASE - NV271
21 - 623
TRANSFER CASE - NV271
TABLE OF CONTENTS
page
page
TRANSFER CASE - NV271
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 652
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 623
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 623
DIAGNOSIS AND TESTING - TRANSFERCASE - NV271
. . . . . . . . . . . . . . . . . . . . . . . 624
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 625
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 635
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 635
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 649
SPECIFICATIONSTRANSFER CASE - NV271
. . . . . . . . . . . . . 649
SPECIAL TOOLS
TRANSFER CASE NV271/NV273 . . . . . . . . . 650
EXTENSION HOUSING SEAL AND DUST BOOT
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
TRANSFER CASE - NV271
DESCRIPTIONThe NV271 transfer case is a part-time transfer case with a low-range gear system. It provides three operating ranges plus a NEUTRAL position. The low range position provides a gear reduction ratio of 2.72:1 for increased low speed torque capability.
The gear cases and extension are all of aluminum (Fig. 1). Drive sprockets and an interconnecting drive chain are used to transmit engine torque to the front/ rear propeller shafts. The mainshaft, input gear and front output shaft are supported by ball and needle bearings.
IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear case of every transfer case. The 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
OPERATING RANGE
Transfer case operating ranges are: † 2H (2-wheel drive) † 4H (4-wheel drive) † 4LO (4-wheel drive low range
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 652
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 653
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 653POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 654
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 654
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 654
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 654SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 655
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 656
ADJUSTMENTSADJUSTMENT - SHIFT LEVER
. . . . . . . . . . 657
Fig.1TransferCase-FrontView
1 - TRANSFER CASE 2 - MANUAL LEVER 3 - POSITION SENSOR
The 2H range is for use on any road surface at any
time.
The 4H 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 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.
21 - 624
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
DR
A straight line shift pattern is used with a NEU- TRAL detent. Lever range positions are imprinted in the shift knob.
SHIFTING
The transfer case can be shifted between the 2H and 4H operating ranges while the vehicle is in motion. The vehicle must have the transmission placed in NEUTRAL, or the clutch depressed in the case of a manual transmission, and be moving less than 2-3 MPH when shifting into and out of the 4L operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV271
Before beginning repair on a suspected transfer case malfunction, check all other driveline compo- nents beforehand.
The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires, transmission, or clutch instead. If all other driveline components are in good condition and operating properly, refer to the Diagnosis Chart for further information.
Fig.2TransferCase-RearView
1 - TRANSFER CASE 2 - IDENTIFICATION TAG
SHIFT MECHANISM
The transfer case is operated by an adjustable floor mounted shift linkage. The transfer case shift lever is directly attached to the shift sector. The sector operates the range and mode forks within the trans- fer case.
DIAGNOSIS CHART
Condition
Possible Cause
Correction
Transfer Case difficult to shift or will not shift into desired range.
1) Vehicle speed too great to permit shifting.
2) If vehicle was operated for an extended period in 4H on a dry paved surface, the driveline torque load may be causing a bind.
3) Transfer case external shift linkage binding.
4) Insufficient or incorrect lubricant.
5) Internal components binding, worn, or damaged.
Transfer Case noisy in all operating ranges.
1) Insufficient or incorrect lubricant.
1) Stop vehicle and shift into desired range. Or, reduce speed to below 3-4 km/h (2-3 mph) before attempting the shift.
2) Stop vehicle and shift the transmission into neutral. Shift the transfer case to 2H and operate vehicle in 2H on dry paved surfaces. 3) Lubricate, repair, or replace linkage bushings, or tighten loose components as necessary. 4) Drain and refill to edge of fill hole with MoparT ATF +4, Automatic Transmission fluid. 5) Disassemble the transfer case and replace worn or damaged components as necessary.
1) Drain and refill to edge of fill hole with MoparT ATF +4, Automatic Transmission fluid.
DR TRANSFER CASE - NV271 (Continued)
TRANSFER CASE - NV271
21 - 625
Condition
Possible Cause
Correction
Noisy in, or jumps out of, four wheel drive low range.
1) Transfer case not completely engaged in 4L position.
Lubricant leaking from output shaft seal or vent.
2) Shift linkage out of adjustment. 3) Shift linkage loose or binding.
4) Range fork damaged, inserts worn, or fork is binding on the shift rail. 5) Low range gear worn or damaged.
1) Transfer case overfilled.
2) Vent closed or restricted.
3) Output shaft seals damaged or installed incorrectly.
1) With the transmission in NEUTRAL, or the clutch depressed in the case of a manual transmission and the vehicle moving under 3-4 km/h (2-3 mph), shift the transfer case to NEUTRAL and then shift into the 4L position.
2) Adjust linkage. 3) Tighten, lubricate, or repair linkage as necessary. 4) Disassemble unit and repair as necessary.
5) Disassemble unit and repair as necessary.
1) Drain lubricant to the correct level.
2) Clear or replace vent as necessary. 3) Replace seal as necessary. Check to ensure that another component, the propeller shaft slip yoke for example, is not causing damage to seal.
Abnormal tire wear.
1) Extended operation on hard, dry surfaces in the 4H position.
1) Operate vehicle in the 2H position on hard, dry surfaces.
(4) Remove transfer case drain plug and drain
under vehicle.
REMOVAL
(1) Raise and support vehicle. (2) Remove skid plate, if equipped. (Refer to 13 - FRAMES & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
lubricant into container.
(5) Disconnect vent hose and transfer case position
sensor connector.
(6) Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy access. Use channel lock style pliers to press rod out of lever grommet.
(7) Support transmission with jack stand. (8) Mark front and rear propeller shafts for assem-
bly reference.
(9) Remove front and rear propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER SHAFT - REMOVAL)
nut.
(10) Support
transfer
case with suitable jack.
Secure transfer case to jack with safety chains.
(11) Remove nuts attaching transfer case to trans-
mission.
(12) Move transfer case assembly rearward until
free of transmission output shaft.
(13) Lower jack and move transfer case from
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubri- cant remaining in case.
COMPANION FLANGE AND EXTENSION HOUSING
(1) Install two bolts 180° apart into the front out-
put shaft companion flange.
(2) Place holder over the bolts and against the
companion flange (Fig. 3).
(3) Remove and discard the front companion flange
21 - 626
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
(4) Remove the companion flange from the front output shaft. It may be necessary to use Flange puller 8992 to remove the companion flange.
DR
(7) Remove rear extension bolts (Fig. 5).
Fig.3RemoveCompanionFlangeNut
1 - EXTENSION HOUSING 2 - BOLTS
Fig.5RemoveExtensionHousingBolts
1 - HOLDER 6719
2 - BOLTS(5) Use a suitable chisel or pry tool to remove the
rear extension housing dust boot (Fig. 4).
(6) Use a suitable chisel or pry tool to remove the
rear extension housing seal.
(8) Remove rear extension housing (Fig. 6). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.
Fig.4RemoveExtensionHousingDustBoot
1 - EXTENSION HOUSING 2 - DUST BOOT
Fig.6RemoveExtensionHousing
1 - REAR CASE HALF 2 - EXTENSION HOUSING
TRANSFER CASE - NV271
21 - 627
(3) Remove rear case-to-front case bolts (Fig. 9).
DR TRANSFER CASE - NV271 (Continued) OIL PUMP AND REAR CASE
(1) Disengage the oil pump pick-up tube (Fig. 7)
from the oil pump.
NOTE: The oil pump pick-up tube seals to the oil pump with an o-ring. Verify that the o-ring was removed with the tube and is in good condition. Replace the o-ring if necessary.
(2) Remove the oil pump (Fig. 8).
Fig.9RemoveCaseHalfBolts
1 - FRONT CASE HALF 2 - REAR CASE HALF 3 - BOLTS
(4) Remove the rear output shaft bearing inner snap-ring (Fig. 10) from the output shaft using suit- able snap-ring pliers.
Fig.7DisengageTheOilPick-upFromOilPump 1 - OIL PUMP 2 - OIL PICK-UP TUBE
Fig.8RemoveOilPump
1 - REAR CASE HALF 2 - REAR OUTPUT SHAFT 3 - OIL PUMP
Fig.10RemoveRearBearingInnerSnap-Ring
1 - OUTPUT SHAFT 2 - REAR CASE HALF 3 - SNAP-RING
21 - 628
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
DR
(5) Remove the rear output shaft bearing inner
snap-ring (Fig. 11) from the output shaft.
(6) Loosen rear case with pry tool to break sealer
bead. Insert tool at each end of case (Fig. 12).
(7) Unseat rear case from alignment dowels. (8) Remove the rear case from the front case (Fig.
13).
Fig.11RemoveRearBearingInnerSnap-Ring
1 - OUTPUT SHAFT 2 - REAR CASE HALF 3 - SNAP-RING
Fig.13RemoveRearCaseHalf
1 - FRONT CASE HALF 2 - REAR CASE HALF
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove the oil pick-up tube (Fig. 14) and
screen from the front case half.
Fig.12SeparateFrontandRearCaseHalves
1 - FRONT CASE HALF 2 - REAR CASE HALF
Fig.14RemoveOilPick-UpTubeandScreen
1 - FRONT CASE HALF 2 - OIL SCREEN 3 - PICK-UP TUBE
DR TRANSFER CASE - NV271 (Continued)
(2) Remove the shift rail spring (Fig. 15).
TRANSFER CASE - NV271
21 - 629
Fig.15RemoveShiftRailSpring
1 - SHIFT RAIL 2 - SPRING
(3) Remove the front output shaft drive sprocket
retaining ring (Fig. 16).
retaining ring (Fig. 17).
(4) Remove the rear output shaft drive sprocket
Fig.17RemoveRearOutputShaftSprocket
RetainingRing
1 - REAR OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
(5) Pull front sprocket (Fig. 18), rear sprocket, and chain upward until clear of the front and rear output shaft sprocket splines.
(6) Remove chain and sprockets as an assembly.
Fig.16RemoveFrontOutputShaftSprocket
RetainingRing
1 - FRONT OUTPUT SHAFT 2 - DRIVE SPROCKET 3 - RETAINING RING
Fig.18RemoveDriveChainandSprockets
1 - FRONT CASE HALF 2 - CHAIN 3 - DRIVE SPROCKETS
TRANSFER CASE - NV271
21 - 630
TRANSFER CASE - NV271 (Continued) SHIFT FORKS AND MAINSHAFT(1) Shift transfer case into NEUTRAL. (2) Remove nut that retains the shift lever to sec- tor shaft. Then remove shift lever (Fig. 19) and spacer from the shaft.
(3) Remove the sector support with Socket 9033. (4) Remove the transfer case position sensor (Fig.
20).
DR
(5) Loosen detent plug (Fig. 21). (6) Remove detent plug, spring, and plunger (Fig. 22). Note that the plug has an O-ring seal. Remove and discard this seal.
Fig.21LoosentheDetentPlug
1 - FRONT CASE HALF 2 - DETENT PLUG
Fig.19RemoveManualShiftLever
1 - SHIFT SECTOR 2 - SECTOR SUPPORT 3 - MANUAL SHIFT LEVER
Fig.20RemovePositionSensor
1 - FRONT CASE 2 - POSITION SENSOR
Fig.22RemoveDetentplug,Spring,andPlunger 1 - FRONT CASE HALF 2 - DETENT PLUG 3 - SPRING 4 - PLUNGER
DR TRANSFER CASE - NV271 (Continued)
TRANSFER CASE - NV271
21 - 631
(7) Using a screw mounted in a slide hammer,
remove the front output shaft seal.
(8) Remove the front output shaft snap-ring (Fig.
23).
(10) Pull mainshaft assembly out of input gear,
mode sleeve, and case (Fig. 25).
Fig.23RemoveFrontOutputShaftBearingInner
Snap-Ring
1 - FRONT CASE HALF 2 - SNAP-RING
(9) Remove front output shaft from bearing in case
(Fig. 24).
Fig.25RemoveMainshaftAssembly
1 - FRONT CASE HALF 2 - MAINSHAFT ASSEMBLY
(11) Remove mode fork, mode sleeve, and shift rail as assembly (Fig. 26). Note which way the sleeve fits in the fork (long side of sleeve goes to front or the points on the sleeve teeth go to the rear of case).
Fig.24RemoveFrontOutputShaft
1 - FRONT CASE 2 - FRONT OUTPUT SHAFT
Fig.26RemoveModeFork,Sleeve,andShiftRail
Assembly
1 - SHIFT RAIL 2 - MODE FORK 3 - MODE SLEEVE
21 - 632
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
(12) Remove range fork and hub as an assembly (Fig. 27). Note fork position for installation reference.
(13) Remove shift sector (Fig. 28).
DR
MAINSHAFT
(1) Remove the clutch gear (Fig. 29) from the out-
put shaft.
Fig.27RangeForkAndHubRemoval
1 - RANGE HUB 2 - RANGE FORK
Fig.29RemoveClutchGear
1 - OUTPUT SHAFT 2 - CLUTCH GEAR 3 - MODE HUB
(2) Remove the mode hub retaining ring (Fig. 30)
from the mainshaft.
Fig.28RemoveShiftSector
1 - SHIFT SECTOR
Fig.30RemoveModeHubRetainingRing
1 - MAINSHAFT 2 - MODE HUB 3 - RETAINING RING
DR TRANSFER CASE - NV271 (Continued)
(3) Remove the mode hub (Fig. 31) from the main-
shaft.
TRANSFER CASE - NV271
21 - 633
INPUT AND PLANETARY GEAR
(1) Remove input gear seal with suitable screw
and slide hammer.
(2) Remove input gear retaining ring (Fig. 33) with
heavy duty snap-ring pliers.
Fig.31RemoveModeHub
1 - MAINSHAFT 2 - MODE HUB
(4) Remove the drive sprocket drive hub (Fig. 32)
from the mainshaft.
Fig.33RemoveInputGearRetainingRing
1 - INPUT GEAR 2 - RETAINING RING
(3) Place front case in horizontal position. Then remove input gear and low range gear as an assem- bly (Fig. 34). Tap gear out of bearing with plastic mallet, if necessary.
Fig.34RemoveInputPlanetaryAssembly
1 - FRONT CASE 2 - INPUT PLANETARY ASSEMBLY
Fig.32RemovetheDriveSprocketDriveHub
1 - MAINSHAFT 2 - DRIVE SPROCKET DRIVE HUB
21 - 634
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
DR
(4) Remove snap-ring that retains input gear in
the low range gear (Fig. 35).
(5) Remove retainer (Fig. 36). (6) Remove front thrust plate (Fig. 37).
Fig.35RemoveInputGearRetainingRing
1 - INPUT GEAR 2 - RETAINING RING
Fig.37RemoveInputGearThrustPlate
1 - INPUT GEAR 2 - THRUST PLATE
(7) Remove input gear (Fig. 38).
Fig.36RemoveInputGearRetainer
1 - INPUT GEAR 2 - RETAINER
Fig.38RemoveInputGearFromPlanetary
1 - INPUT GEAR 2 - LOW RANGE PLANETARY
DR TRANSFER CASE - NV271 (Continued)
(8) Remove bottom tabbed thrust washer from low
range planetary (Fig. 39).
Fig.39RemoveBottomInputGearThrustPlate
1 - PLANETARY 2 - THRUST PLATE
TRANSFER CASE - NV271
21 - 635
CLEANING
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and 3M™ all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone, however, replace any part that is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320-400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 40). Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery cloth if necessary.
1 - PLANETARY CARRIER 2 - REAR THRUST WASHER 3 - FRONT THRUST WASHER
Fig.40InputGearAndCarrierComponents 4 - CARRIER LOCK RING 5 - CARRIER LOCK RETAINING RING 6 - INPUT GEAR
21 - 636
TRANSFER CASE - NV271 (Continued)TRANSFER CASE - NV271
Examine the carrier body and pinion gears for wear or damage. Check the pinion gear thrust wash- ers on the pinon pins for damage. The carrier will have to be replaced as an assembly if the body, pin- ion pins, or pinion gears are damaged.
Check the lock ring and both thrust washers for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift rail (Fig. 41). Minor nicks on the shift rail can be smoothed with 320-400 grit emery cloth.
DR
Fig.42ShiftForkAndWearPadLocations
1 - RANGE FORK 2 - MODE FORK 3 - WEAR PADS (SERVICEABLE) 4 - WEAR PADS (SERVICEABLE)
Fig.41Shiftforks
