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21 - 581
(9) Fill the transmission with the recommended
fluid.
TRANSMISSION RANGE SENSOR DESCRIPTION
The Transmission Range Sensor (TRS) is part of the solenoid module, which is mounted to the top of the valve body inside the transmission.
switch contact pins that:
The Transmission Range Sensor (TRS) has five † Determine shift lever position † Supply ground to the Starter Relay in Park and † Supply +12 V to the backup lamps in Reverse
Neutral only.
only.
The TRS also has an integrated temperature sen- communicates transmission
sor temperature to the TCM and PCM.
(thermistor)
that
Fig.125CheckingTorqueConverterSeating-Typical 1 - SCALE 2 - STRAIGHTEDGE
TRANSMISSION CONTROL RELAY DESCRIPTION
The relay is supplied fused B+ voltage, energized by the TCM, and is used to supply power to the sole- noid pack when the transmission is in normal oper- ating mode.
OPERATION
When the relay is “off”, no power is supplied to the solenoid pack and the transmission is in “limp-in” mode. After a controller reset, the TCM energizes the relay. Prior to this, the TCM verifies that the con- tacts are open by checking for no voltage at the switched battery terminals. After this is verified, the voltage at the solenoid pack pressure switches is checked. After the relay is energized, the TCM mon- itors the terminals to verify that the voltage is greater than 3 volts.
OPERATION
The Transmission Range Sensor (TRS) communi- cates shift lever position to the TCM as a combina- tion of open and closed switches. Each shift lever position has an assigned combination of switch states (open/closed) that the TCM receives from four sense circuits. The TCM interprets this information and determines the appropriate transmission gear posi- tion and shift schedule.
There are many possible combinations of open and closed switches (codes). Seven of these possible codes are related to gear position and five are recognized as “between gear” codes. This results in many codes which should never occur. These are called “invalid” codes. An invalid code will result in a DTC, and the TCM will then determine the shift lever position based on pressure switch data. This allows reasonably normal transmission operation with a TRS failure.
GEAR
Park
Temp 1
Reverse Temp 2
Neutral 1
Neutral 2
Temp 3
Drive Temp 4
Manual 2
Temp 5
Manual 1C5
CL CL OP OP OP OP OP OP OP CL CL CL
C4
OP OP OP OP OP CL CL CL CL CL OP OP
C3
OP OP OP CL CL CL CL CL OP OP OP CL
C2
CL CL CL CL CL CL CL OP OP OP OP OP
C1
CL OP OP OP CL CL OP OP OP OP OP OP
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AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
TRANSMISSION SOLENOID/ TRS ASSEMBLY DESCRIPTION
The transmission solenoid/TRS assembly is inter- nal to the transmission and mounted on the valve body assembly (Fig. 126). The assembly consists of six solenoids that control hydraulic pressure to the six friction elements (transmission clutches), and the torque converter clutch. The pressure control sole- noid is located on the side of the solenoid/TRS assem- bly. The solenoid/TRS assembly also contains five pressure switches that feed information to the TCM.
The solenoids receive electrical power from the Transmission Control Relay through a single wire. The TCM energizes or operates the solenoids individ- ually by grounding the return wire of the solenoid as necessary. When a solenoid is energized, the solenoid valve shifts, and a fluid passage is opened or closed (vented or applied), depending on its default operat- ing state. The result is an apply or release of a fric- tional element.
The MS and UD solenoids are normally applied to allow transmission limp-in in the event of an electri- cal failure.
The continuity of the solenoids and circuits are periodically tested. Each solenoid is turned on or off depending on its current state. An inductive spike should be detected by the TCM during this test. If no spike is detected, the circuit is tested again to verify the failure. In addition to the periodic testing, the solenoid circuits are tested if a speed ratio or pres- sure switch error occurs.
PRESSURE SWITCHES
The TCM relies on five pressure switches to moni- tor fluid pressure in the L/R, 2C, 4C, UD, and OD hydraulic circuits. The primary purpose of these switches is to help the TCM detect when clutch cir- cuit hydraulic failures occur. The switches close at 23
psi and open at 11 psi, and simply indicate whether or not pressure exists. The switches are continuously monitored by the TCM for the correct states (open or closed) in each gear as shown in the following charts 45RFE PRESSURE SWITCH STATES and 545RFE PRESSURE SWITCH STATES :45RFE PRESSURE SWITCH STATES
GEAR
P/N 1ST 2ND 2ND PRIME
FOURTH
L/R
OP CL CL* OP
OP
OP OP
2C
OP OP OP CL
OP
OP OP
4C
OP OP OP OP
CL
OP CL
UD
OP OP CL CL
CL
CL OP
OD
OP OP OP OP
OP
CL CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
Fig.126TransmissionSolenoid/TRSAssembly
1 - PRESSURE CONTROL SOLENOID 2 - TRANSMISSION RANGE SELECTOR PLATE 3 - 23-WAY CONNECTOR 4 - SOLENOID PACK 5 - TRANSMISSION RANGE SENSOR 6 - VALVE BODY
OPERATION
SOLENOIDS
Solenoids are used to control the L/R, 2C, 4C, OD, and UD friction elements. The reverse clutch is con- trolled by line pressure and the position of the man- ual valve in the valve body. All the solenoids are contained within the Solenoid and Pressure Switch Assembly. The solenoid and pressure switch assembly contains one additional solenoid, Multi-Select (MS), which serves primarily to provide 2nd and 3rd gear limp-in operation.
DR TRANSMISSION SOLENOID/TRS ASSEMBLY (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 583
545RFE PRESSURE SWITCH STATES
GEAR
P/N 1ST 2ND 2ND PRIME
4TH 5TH
L/R
OP CL CL* OP
OP
OP OP OP
2C
OP OP OP CL
OP
OP OP CL
4C
OP OP OP OP
CL
OP CL OP
UD
OP OP CL CL
CL
CL OP OP
OD
OP OP OP OP
OP
CL CL CL
*L/R is closed if output speed is below 100 rpm in
Drive and Manual 2. L/R is open in Manual 1.
A Diagnostic Trouble Code (DTC) will set if the TCM senses any switch open or closed at the wrong time in a given gear.
REMOVAL
(1) Remove the valve body from the transmission
(Fig. 127).
Fig.128TtransmissionSolenoid/TRSAssembly
1 - SOLENOID PACK BOLTS (15)
Screws
dowels are fully seated in the valve body and that the TRS switch contacts are properly positioned in the selector plate
(3) Install the screws to hold the transmission
solenoid/TRS assembly onto the valve body.
(4) Tighten the solenoid assembly screws adjacent to the arrows cast into the bottom of the valve body first. Tighten the screws to 5.7 N·m (50 in.lbs.).
(5) Tighten the remainder of the solenoid assembly
screws to 5.7 N·m (50 in.lbs.).
(6) Install the valve body into the transmission.
TRANSMISSION TEMPERATURE SENSOR DESCRIPTION
The transmission temperature sensor is a ther- mistor that is integral to the Transmission Range Sensor (TRS).
OPERATION
The transmission temperature sensor is used by the TCM to sense the temperature of the fluid in the sump. Since fluid temperature can affect transmis- sion shift quality and convertor lock up, the TCM requires this information to determine which shift schedule to operate in.
Calculated Temperature
A failure in the temperature sensor or circuit will result in calculated temperature being substituted for actual temperature. Calculated temperature is a pre-
Fig.127ValveBodyBolts
1 - VALVE BODY TO CASE BOLT (6)
(2) Remove the screws holding the transmission solenoid/TRS assembly onto the valve body (Fig. 128). (3) Separate the transmission solenoid/TRS assem-
bly from the valve body.
INSTALLATION
(1) Place TRS selector plate in the PARK position. (2) Position the transmission solenoid/TRS assem- bly onto the valve body. Be sure that both alignment
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TRANSMISSION TEMPERATURE SENSOR (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
dicted fluid temperature which is calculated from a combination of inputs: † Battery (ambient) temperature † Engine coolant temperature † In-gear run time since start-up
VALVE BODY DESCRIPTION
The valve body consists of a cast aluminum valve body, a separator plate, and a transfer plate. The valve body contains valves and check balls that con- trol fluid delivery to the torque converter clutch, bands, and frictional clutches. The valve body con- tains the following components (Fig. 129) and (Fig. 130):† Solenoid switch valve † Manual valve † Low/reverse switch valve † 5 Accumulators † 7 check balls
Fig.130CheckBallLocations
1 - LOW/REVERSE ACCUMULATOR 2 - LOW/REVERSE SWITCH VALVE 3 - UPPER VALVE BODY 4 - MANUAL VALVE 5 - SOLENOID SWITCH VALVE
Fig.129ValveBodyComponents
6 - OVERDRIVE ACCUMULATOR 7 - UNDERDRIVE ACCUMULATOR 8 - 4C ACCUMULATOR 9 - 2C ACCUMULATOR
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 585
LOW/REVERSE SWITCH VALVE
The low/reverse switch valve allows the low/reverse clutch to be operated by either the LR/CC solenoid or the MS solenoid.
REMOVAL
The valve body can be removed for service without
having to remove the transmission assembly.
The valve body can be disassembled for cleaning and inspection of the individual components. (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 45RFE/VALVE BODY - DISASSEMBLY)
(1) Shift transmission into PARK. (2) Raise vehicle. (3) Disconnect wires at the solenoid and pressure
switch assembly connector.
(4) Position drain pan under transmission oil pan. (5) Remove transmission oil pan. (6) Remove the primary oil filter from valve body.
(Fig. 132)
Fig.132RemovePrimaryOilFilter
1 - PRIMARY OIL FILTER 2 - COOLER RETURN FILTER 3 - COOLER RETURN FILTER BYPASS VALVE 4 - VALVE BODY
DR VALVE BODY (Continued) OPERATION
NOTE: Refer to the Hydraulic Schematics for a visual aid in determining valve location, operation and design.
SOLENOID SWITCH VALVE
The Solenoid Switch Valve (SSV) controls the direc- tion of the transmission fluid when the L/R-TCC sole- noid is energized.
When shifting into 1st gear, a special hydraulic sequence is performed to ensure SSV movement into the downshifted position. The L/R pressure switch is monitored to confirm SSV movement. If the move- ment is not confirmed (the L/R pressure switch does not close), 2nd gear is substituted for 1st. A DTC will be set after three unsuccessful attempts are made to get into 1st gear in one given key start.
MANUAL VALVE
The manual valve is a relay valve. The purpose of the manual valve is to direct fluid to the correct cir- cuit needed for a specific gear or driving range. The manual valve, as the name implies, is manually oper- ated by the driver with a lever located on the top of the valve body. The valve is connected mechanically by a cable to the gearshift mechanism. The valve is held in each of its positions by a roller detent spring (Fig. 131) that engages the “roostercomb” of the TRS selector plate.
Fig.131TRSSelectorPlateandDetentSpring
1 - TRS SELECTOR PLATE 2 - DETENT SPRING 3 - CLUTCH PASSAGE SEALS
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VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
(7) Remove bolts attaching valve body to transmis-
sion case (Fig. 133).
(8) Lower the valve body and work the electrical
connector out of transmission case.
(9) Separate the valve body from the transmission.
Fig.134SolenoidandPressureSwitchAssembly
1 - SOLENOID PACK BOLTS (15)
Screws
Fig.133ValveBodyBolts
1 - VALVE BODY TO CASE BOLT (6)
DISASSEMBLY
(1) Remove the screws holding the solenoid and pressure switch assembly to the valve body (Fig. 134). Do not remove the screws on the top of the sole- noid and pressure switch assembly.
(2) Separate the solenoid and pressure switch
assembly from the valve body.
(3) Remove the screw holding the detent spring
(Fig. 135) onto the valve body.
(4) Remove the detent spring from the valve body. (5) Remove the TRS selector plate from the valve
body and the manual valve.
(6) Remove the clutch passage seals from the valve
body, if necessary.
Fig.135ValveBodyExternalComponents
1 - TRS SELECTOR PLATE 2 - DETENT SPRING 3 - CLUTCH PASSAGE SEALS
DR VALVE BODY (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 587
(7) Remove the screws holding the accumulator
cover onto the valve body (Fig. 136).
(8) Remove the accumulator springs and pistons from the valve body. Note which accumulator piston and spring belong in each location.
(9) Place the valve body on the bench with the
transfer plate upward.
NOTE: The valve body contains seven check balls. The transfer plate must be placed upward to pre- vent losing the check balls when the transfer plate is removed from the valve body.
(10) Remove the screws holding the valve body to
the valve body transfer plate.
(11) Remove the transfer plate from the valve body. Note the location of all check balls (Fig. 137). (12) Remove the check balls from the valve body.
Fig.137CheckBallLocations
1 - LOW/REVERSE ACCUMULATOR 2 - LOW/REVERSE SWITCH VALVE 3 - UPPER VALVE BODY 4 - MANUAL VALVE 5 - SOLENOID SWITCH VALVE
Fig.136ValveBodyComponents
6 - OVERDRIVE ACCUMULATOR 7 - UNDERDRIVE ACCUMULATOR 8 - 4C ACCUMULATOR 9 - 2C ACCUMULATOR
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VALVE BODY (Continued)AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
(13) Remove the retainers securing the solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body and remove the associated valve and spring. Tag each valve and spring combination with location information to aid in assembly. (Fig. 138)
Dry all except the electrical parts with compressed air. Make sure all passages are clean and free from obstructions. Do not use rags or shop towels to dry or wipe off valve body components. Lint from these materials can stick to valve body parts, interfere with valve operation, and clog filters and fluid passages.
Fig.138ValveBodyComponents
1 - SOLENOID SWITCH VALVE 2 - MANUAL VALVE 3 - LOW REVERSE SWITCH VALVE 4 - LOW REVERSE ACCUMULATOR 5 - 2ND CLUTCH ACCUMULATOR 6 - UNDERDRIVE ACCUMULATOR 7 - OVERDRIVE ACCUMULATOR 8 - 4TH CLUTCH ACCUMULATOR 9 - CHECK BALLS (7)
CLEANING
Clean the valve housings, valves, plugs, springs, and separator plates with a standard parts cleaning solution only. Do not use gasoline, kerosene, or any type of caustic solution. (Fig. 139)
Do not immerse any of the electrical components in cleaning solution. Clean the electrical components by wiping them off with dry shop towels only.
Fig.139ValveBodyComponents
1 - SOLENOID SWITCH VALVE 2 - MANUAL VALVE 3 - LOW REVERSE SWITCH VALVE 4 - LOW REVERSE ACCUMULATOR 5 - 2ND CLUTCH ACCUMULATOR 6 - UNDERDRIVE ACCUMULATOR 7 - OVERDRIVE ACCUMULATOR 8 - 4TH CLUTCH ACCUMULATOR 9 - CHECK BALLS (7)
INSPECTION
Inspect all of the valve body mating surfaces for scratches, nicks, burrs, or distortion. Use a straight- edge to check surface flatness. Minor scratches may be removed with crocus cloth using only very light pressure.
Minor distortion of a valve body mating surface may be corrected by smoothing the surface with a sheet of crocus cloth. Position the crocus cloth on a surface plate, sheet of plate glass or equally flat sur- face. If distortion is severe or any surfaces are heavily scored, the valve body will have to be replaced.
DR VALVE BODY (Continued)
AUTOMATIC TRANSMISSION - 45RFE/545RFE
21 - 589
Inspect
(Fig. 140)
the valves and plugs
for scratches, burrs, nicks, or scores. Minor surface scratches on steel valves and plugs can be removed with crocus cloth but do not round off the edges of the valve or plug lands. Maintaining sharpness of these edges is vitally important. The edges prevent foreign matter from lodging between the valves and plugs and the bore.
Valve body bores do not change dimensionally with use. If the valve body functioned correctly when new, it will continue to operate properly after cleaning and inspection. It should not be necessary to replace a valve body assembly unless it is damaged in han- dling.
Inspect all the accumulator bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the accumulator springs. The springs must be free of distortion, warpage or broken coils.
Inspect all the fluid seals on the valve body (Fig. 141). Replace any seals that are cracked, distorted, or damaged in any way. These seals pass fluid pressure directly to the clutches. Any pressure leak at these points, may cause transmission performance prob- lems.
Fig.140ValveBodyComponents
1 - SOLENOID SWITCH VALVE 2 - MANUAL VALVE 3 - LOW REVERSE SWITCH VALVE 4 - LOW REVERSE ACCUMULATOR 5 - 2ND CLUTCH ACCUMULATOR 6 - UNDERDRIVE ACCUMULATOR 7 - OVERDRIVE ACCUMULATOR 8 - 4TH CLUTCH ACCUMULATOR 9 - CHECK BALLS (7)
Inspect all the valve and plug bores in the valve body. Use a penlight to view the bore interiors. Replace the valve body if any bores are distorted or scored. Inspect all of the valve body springs. The springs must be free of distortion, warpage or broken coils.
Trial fit each valve and plug in its bore to check freedom of operation. When clean and dry, the valves and plugs should drop freely into the bores.
Fig.141ValveBodySeals
1 - UNDERDRIVE ACCUMULATOR (2 SPRINGS) 2 - 4TH CLUTCH ACCUMULATOR (2 SPRINGS) 3 - 2ND CLUTCH ACCUMULATOR (2 SPRINGS) 4 - LOW REVERSE ACCUMULATOR (2 SPRINGS) 5 - LOW/REVERSE PASSAGE SEAL 6 - 2ND CLUTCH PASSAGE SEAL 7 - 4TH CLUTCH PASSAGE SEAL 8 - OVERDRIVE ACCUMULATOR (1 SPRING)
(4) Install the valve body check balls into their
switch assembly connector with petroleum jelly.
AUTOMATIC TRANSMISSION - 45RFE/545RFE
DR
21 - 590
VALVE BODY (Continued) ASSEMBLY(1) Lubricate valves, springs, and the housing
valve bores with clean transmission fluid.
(2) Install solenoid switch valve, manual valve, and the low/reverse switch valve into the valve body. (3) Install the retainers to hold each valve into the
valve body.
proper locations.
(5) Position the transfer plate onto the valve body. (6) Install the screws to hold the transfer plate to the valve body. Tighten the screws to 5.6 N·m (50 in. lbs.).
(7) Install the accumulator pistons and springs into the valve body in the location from which they were removed. Note that all accumulators except the overdrive have two springs. The overdrive accumula- tor piston has only one spring.
(8) Position the accumulator cover onto the valve
body.
(9) Install the screws to hold the accumulator cover onto the valve body. Tighten the screws to 4.5
N·m (40 in. lbs.).(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install
the solenoid and pressure switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and pressure switch assembly onto the valve body. Tighten the screws to 5.7 N·m (50 in. lbs.). Tighten the screws adjacent to the arrows cast into the bot- tom of the transfer plate first.
(13) Position the detent spring onto the valve body. (14) Install the screw to hold the detent spring onto the valve body. Tighten the screw to 4.5 N·m (40
in. lbs.).(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the solenoid and pressure switch assembly. Replace seals if cut or worn.
(2) Place TRS selector plate in the PARK position. (3) Place the transmission in the PARK position. (4) Lubricate seal on the solenoid and pressure
(5) Position valve body in transmission and align the manual lever on the valve body to the pin on the transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N·m (105 in. lbs.) torque.
(8) Install a new primary oil filter seal in the oil pump inlet bore. Seat the seal in the bore with the butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully installed flush against the oil pump body. DO NOT install the seal onto the filter neck and attempt to install the filter and seal as an assembly. Damage to the transmission will result.
(9) Place replacement filter in position on valve
body and into the oil pump.
(10) Install screw to hold filter to valve body.
Tighten screw to 4.5 N·m (40 in. lbs.) torque.
(11) Connect
the solenoid and pressure switch
assembly connector.
(105 in. lbs.) torque.
Mopart ATF +4.
(12) Install oil pan. Tighten pan bolts to 12 N·m
(13) Lower vehicle and fill
transmission with
(14) Check and adjust gearshift cable, if necessary.
DR
TRANSFER CASE - NV241 GENII
21 - 591
TRANSFER CASE - NV241 GENII
TABLE OF CONTENTS
page
page
TRANSFER CASE - NV241 GENII
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 616
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 591
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 591
DIAGNOSIS AND TESTING - TRANSFERCASE - NV241 GENII
. . . . . . . . . . . . . . . . . . 592
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 593
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 602
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 614
SPECIFICATIONSTRANSFER CASE - NV241 GENII
. . . . . . . . 614
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243 . . . . . . . . 615
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
TRANSFER CASE - NV241
GENII DESCRIPTIONThe NV241 GENII transfer case is a part-time transfer case with a low-range gear system. It pro- vides three operating ranges plus a NEUTRAL posi- tion. 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)
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
FRONT OUTPUT SHAFT SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 618POSITION SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 618
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 619
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 619SHIFT LEVER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 621
ADJUSTMENTSADJUSTMENT - SHIFT LEVER
. . . . . . . . . . 622
Fig.1TransferCase-FrontView
1 - TRANSFER CASE 2 - MANUAL LEVER 3 - POSITION SENSOR
† 4H (4-wheel drive) † 4LO (4-wheel drive low range 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
21 - 592
TRANSFER CASE - NV241 GENII (Continued)TRANSFER CASE - NV241 GENII
DR
operates the range and mode forks within the trans- fer case.
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 - NV241 GENII
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
power in off road situations. Low range reduction ratio is 2.72:1.
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
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 - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 593
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.
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.
(4) Remove transfer case drain plug and drain
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)
(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
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubri- cant remaining in case.
TRANSFER CASE - NV241 GENII
21 - 594
TRANSFER CASE - NV241 GENII (Continued) SHIFT LEVER AND FRONT OUTPUT SHAFT SEAL(1) Shift transfer case into NEUTRAL. (2) Remove nut that retains the shift lever to sec- tor shaft. Then remove shift lever from shaft (Fig. 3).
DR
Fig.5RemoveSealBoot
1 - SEAL BOOT 2 - SEAL SLINGER
Fig.3RemoveRangeLeverNut
1 - RANGE LEVER
(3) Remove the front propeller shaft seal boot
retaining clamp (Fig. 4).
(4) Remove the front propeller shaft seal boot (Fig.
5).
(5) Remove the front output shaft seal slinger by bending (Fig. 6) the slinger ears away from the transfer case.
Fig.6BendSlingerEars
1 - SLINGER 2 - BEND UPWARD
Fig.4RemoveBootClamp
1 - SEAL BOOT 2 - BOOT CLAMP
DR TRANSFER CASE - NV241 GENII (Continued)
TRANSFER CASE - NV241 GENII
21 - 595
(6) Using a suitable pry tool (Fig. 7), remove the slinger from the output shaft using care not to dam- age the shaft.
(2) Remove rear extension housing (Fig. 9). Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.
Fig.7RemoveSlingerFromShaft
Fig.9RemoveRearExtension
1 - SLINGER 2 - PRY TOOL
(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
