Cleaning; Inspection - Dodge Dakota Sport 2001 Service Manual

21 - 546 TRANSFER CASE - NV233
TRANSFER CASE - NV233 (Continued)
(2) Remove retainer (Fig. 27).
(3) Remove front tabbed thrust washer (Fig. 28).
(4) Remove input gear (Fig. 29).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 30).
Fig. 27 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 28 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER

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.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
Fig. 29 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 30 Rear Tabbed Thrust Washer
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER

INSPECTION

MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket (Fig. 31). 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. 32). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
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