Dodge RAM TRUCK 1500 1995 Service Manual page 1561

21 - 280 IP231 HD/NP241/NP241 HD TRANSFER ' A ^
Fig. 2 Transfer Case identification Tag
lation. The new seal must be seated below the edge
of the seal bore in the front case. Refer to the over­
haul procedures for seal installation.
SERVICE DIAGNOSIS
Before attempting to repair 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 Service Diagnosis
chart for further information.
CHECKING FLUID LEVEL
Correct fluid level for the NP231 HD, NP241, or
NP241 HD transfer case is to the bottom edge of the
fill plug hole.
A correct m e t h o d of c h e c k i n g fluid l e v e l i s im­
portant. Am a c c u r a t e check r e q u i r e s t h a t t h e
transfer case b e l e v e l .
If fluid level is checked with the vehicle parked on
the shop floor, be sure the floor area used is level. If
fluid level is checked with the vehicle raised, use ei­
ther a swivel arm or drive-on type hoist to be sure
the vehicle is level.
FLUID DRIIN/REFILL
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3)" Remove drain and fill plugs and drain lubricant
completely.
(4) Install drain plug. Tighten plug to 41-54 N-m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with Mopar Dexron I I .
(7) Install and tighten fill plug to 41-54 N-m (30-40
ft. lbs.).
(8) Lower vehicle.
IN-VEHICLE SERVICE
The front shaft companion flange, rear extension
seal, output bearing, front shaft seal, and speedome­
ter drive gear can all be serviced with the transfer
case in the vehicle.
The rear extension, rear retainer, and companion
flange, can all be removed for access while the trans­
fer case is mounted in the vehicle. Removal/installa­
tion procedures are described in the transfer case
disassembly/assembly procedures.
SPEEDOMETER SERVICE
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 3).
(4) Remove speed sensor and speedometer adapter
as assembly.
(5) Remove speed sensor retaining screw and re­
move sensor from adapter.
(6) Remove speedometer pinion from adapter.
(7) Inspect sensor and adapter O-rings (Fig. 3). Re­
move and discard O-rings if worn or damaged.
(8) Inspect terminal pins in speed sensor. Clean
pins with Mopar electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or pins are loose,
severely corroded, or damaged.
SPEEDOMETER INSTALLATION AMD
iMDEXm®
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper­
ation.
(2) Install new O-rings on speed sensor and speed­
ometer adapter if necessary (Fig. 3).
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N-m
(15-27 in. lbs.) torque.
(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 4).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until required range numbers
are at 6 o-clock position. Be sure range index num­
bers correspond to number of teeth on pinion gear.
(10) Install speedometer adapter clamp and retain­
ing screw. Tighten clamp screw to 10-12 N-m (90-110
in. lbs.) torque.