Chrysler DODGE D150 1993 Service Manual page 1361

21 - 360 NP241 TRANSFER CASE
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cone with a minimum of wobble. Also check the syn­
chronizer struts for wear or damage.
Inspect all gear teeth for excessive wear or damage
and check all gear splines for burrs, nicks, wear, or
damage. Remove minor nicks or scratches with an oil
stone. Replace any part exhibiting excessive wear or
damage.
Inspect all snap rings and thrust washers for exces­
sive wear, distortion or damage. Replace worn or
damaged parts.
Inspect the two case halves for cracks, porosity,
damaged mating surfaces, stripped bolt threads, or
distortion. Replace either case half if necessary.
Inspect condition of all needle, roller, ball, and
thrust bearings in the front and rear case halves and
the input gear. Also check condition of the bearing
bores in both cases and in the input gear, rear output
shaft, side gear, and rear retainer. Replace any com­
ponent exhibiting excessive wear or damage.
If the case or input gear bearings require replace­
ment, refer to the Transfer Case Bearing Replace­
ment procedures.
TRANSFER CASE BEARING REPLACEMENT
C A U T I O N : M o s t of the transfer c a s e bearing bores
contain oil feed holes. B e sure replacement bear­
ings d o not block these feed holes.
DRIVE SPROCKET BEARING REPLACEMENT
(1) Remove both drive sprocket bearings simulta­
neously using a shop press, Tool Handle C-4171 and
Remover/Installer Tool C-4697-1 (Fig. 19).
(2) Clean sprocket bearing bore after removing old
bearings.
(3) Before proceeding, note t h a t sprocket bearings
are positioned differently (Fig. 20). Front bearing is
installed flush with end of bore. However, rear bear­
ing is recessed slightly. Be sure to install bearings as
shown in Figure 20.
Fig. 19 Removing Drive Sprocket Bearings
(4) Install new sprocket bearings one at a time
starting with front bearing.
(a) Press front bearing flush with end of bore as
shown (Fig. 20).
(b) Press rear bearing into sprocket until bearing
is 4.6 mm (11/64 in.) below edge of bore.
RR21F32
Fig. 20 Drive Sprocket Bearing Installation
MAINSHAFT PILOT BEARING REPLACEMENT
The mainshaft pilot bearing is located in the input
shaft. The bearing is removed from the shaft bore
with Remover Tool MD-998346 and two appropriate
size backup wrenches (Fig. 21).
The new bearing is installed with Tool Handle
C-4171 and Installer 5065 (Fig. 22).
A shop press is recommended to press the bearing
into place. The bearing is seated when the installer
tool contacts the input shaft.
REPLACING MAINSHAFT REAR (OUTPUT)
BEARING
The mainshaft rear (output) bearing is located in
the rear retainer. The seal must be removed before
the bearing can be replaced.
(1) Remove seal with Remover Tool C-4613 (Fig.
23).