Dodge 2001 Ram 1500 Owner's Manual page 2538

BR/BE
TRANSFER CASE - NV241HD (Continued)
Check a replacement synchronizer ring for proper fit
on the cone with a minimum of wobble. Also check
the synchronizer struts for wear or damage.
Inspect all gear teeth and splines for wear or dam-
age. Also check splines for burrs, or nicks. Remove
minor nicks and scratches with an oil stone. Replace
any part with damaged splines.
It is recommended that all retaining rings be replaced
during overhaul. Most of the retaining rings can be dis-
torted during removal and should not be reused.
Inspect the two case halves, for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary. How-
ever, stripped threads can be repaired with Heli-
Coil™ stainless steel thread inserts. The case vent
tube can be resecured with Loctite™ 680 if necessary.
Inspect the annulus gear. Be sure the gear teeth
are in good condition. Replace the front case and
annulus as an assembly if the gear is damaged.
Check condition of the shift fork pads (Fig. 39).
The pads should be replaced if cracked, worn, or
loose (won't stay on fork).
The shift forks, clutch and sleeve should all be
checked for wear, cracks, or any type of damage (Fig.
40). The shift sector shaft and detents should be
inspected for wear. The mode fork and shift rail are a
one-piece unit. If either part is damaged, replace the
fork and rail as an assembly. Replace the shift rail
cup and spring if they exhibit wear.
1 - SUPPORT SLEEVE
2 - RANGE FORK
3 - SHIFT SECTOR
4 - POPPET PLUNGER, SPRING, SCREW
1 - PADS
2 - PADS
3 - RANGE FORK
4 - MODE FORK
Inspect the planetary thrust washers (Fig. 41)
carefully for wear or damage. Replace both washers
if necessary.
Fig. 40 Shift Fork Components
5 - MODE FORK AND SHIFT RAIL
6 - SPRING
7 - CUP
8 - SLIDING CLUTCH
TRANSFER CASE - NV241HD
Fig. 39 Shift Fork Pads
21 - 903