Dodge dakota 2002 Service Manual page 2430

DR
TRANSFER CASE - NV241 GENII
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 591
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 591
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV241 GENII
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 593
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 602
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 602
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 614
SPECIFICATIONS
TRANSFER CASE - NV241 GENII
SPECIAL TOOLS
TRANSFER CASE - NV241/NV243 . . . . . . . . 615
EXTENSION HOUSING BUSHING AND SEAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
TRANSFER CASE - NV241
GENII
DESCRIPTION
The 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)
TRANSFER CASE - NV241 GENII
TABLE OF CONTENTS
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. . . . . . . . 614
TRANSFER CASE - NV241 GENII
page
INSTALLATION
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
FRONT OUTPUT SHAFT SEAL
REMOVAL
INSTALLATION
POSITION SENSOR
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
SHIFT LEVER
REMOVAL
INSTALLATION
ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
Fig. 1 Transfer Case - Front View
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
. . . . . . . . . . . . . . . . . . . . . . . . 616
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 617
. . . . . . . . . . . . . . . . . . . . . . . . 618
. . . . . . . . . . . . . . . . . . . . . . . . 618
. . . . . . . . . . . . . . . . . . . . . . . . . . 619
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
. . . . . . . . . . . . . . . . . . . . . . . . 619
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
. . . . . . . . . . . . . . . . . . . . . . . . 621
21 - 591
page
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