Dodge RAM TRUCK 1500 1995 Service Manual page 1562

B R
NP231 HD/NP241/NP241 HD TRANSFER CASE 21 - 281
SERVICE DIAGNOSIS
Condition
Possible Cause
Correction
TRANSFER CASE
DIFFICULT TO SHIFT
O i WILL NOT SHIFT
INTO DESIRED
RANGE
TRANSFER CASE
NOISY IN ALL
DRIVE MODES
NOISY IN—OR
J U M P S OUT OF •
FOUR-WHEEL-DRIVE
LOW RANGE
LUBRICANT
LEAKING FROM
OUTPUT SHAFT
SEALS O I FROM
VENT
ABNORMAL
tlRE WEAR
(a) Vehicle speed too great to permit
shifting.
(b) If vehicle was operated for extended
period in 4H mode on dry paved
surface, driveline torque load may
cause difficulty.
(c) Transfer case external shift linkage
binding.
(d) Insufficient or incorrect lubricant.
(e) Internal components binding, worn or
damaged.
(a) Insufficient or incorrect lubricant.
(a) Transfer case not completely engaged
in 4L position.
(b) Shift linkage loose or binding.
(c) Range fork cracked, inserts worn, or
fork is binding on shift rail.
(d) Annulus gear or lockplate work or
damaged.
(a) Transfer case overfilled.
(b) Vent closed or restricted.
(c) Output shaft seals damaged or
installed correctly.
(a) Extended operation on dry hard
surface (paved) roads in 4H range.
(a) Stop vehicle and shift into desired
range. Or reduce speed to 3-4 km/h
(2-3 mph) before attempting to shift.
(b) Stop vehicle, shift transmission to
neutral, shift transfer case to 2H mode
and operate vehicle on 2H on dry
paved surface.
(c) Lubricate, repair or replace linkage, or
tighten loosen components as necessary.
(d) Drain and refill to edge of fill hole with
MOPAR ATF PLUS (Type 7176) or
DEXRON II Automatic Transmission
Fluid.
(e) Disassemble unit and replace worn or
damaged components as necessary.
(a) Drain and refill to edge of fill hole with
MOPAR ATF PLUS (Type 7176) or
DEXRON II Automatic Transmission
Fluid. Check for leaks and repair if
necessary. If unit is still noisy after
drain and refill, disassembly and
inspection may be required to locate
source of noise.
(a) Stop vehicle, shift transfer case to
Neutral, then shift back into 4L position.
(b) Tighten, lubricate, or repair linkage as
necessary.
(c) Disassemble unit and repair as
necessary
(d) Disassemble unit and repair as
necessary
(a) Drain to correct level.
(b) Clear or replace vent if necessary.
(c) Replace seals. Be sure seal lip faces
interior of case when installed. Also be
sure yoke seal surfaces are not scored
or nicked. Remove scores and nicks with
fine sandpaper or replace yoke(s) if
necessary.
(a) Operate in 2H on hard surface (paved)
roads.
J9021-152
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle.
SHIFT LINKAGE ADJUSTMENT
(1) Move shift lever into 2H position.
(2) Raise vehicle.
(3) Loosen shift rod lock bolt at trunnion (Fig. 5).
(4) Check shift rod fit in trunnion. Be sure rod
does not bind in trunnion.
(5) Verify that transfer case shift lever is in 2H po­
sition (Fig. 6).
(6) Tighten shift rod lock bolt to 10 N-m (90 in.
lbs.) torque.
(7) Lower vehicle.
(8) Check shift linkage operation. Be sure transfer
case shifts into and operates properly in all ranges.
TRANSFER CASE REMOVAL
(1) Raise vehicle.
(2) Position drain oil container under transfer case.
(3) Remove transfer case drain plug and drain lu­
bricant into container.
(4) Disconnect wires at vehicle speed sensor.