Transfer Case - NV245

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Fig 1: Identifying Input Gear Bearing

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1 - INPUT GEAR BEARING

2 - FRONT CASE

While holding the retaining ring tabs apart with suitable snap-ring pliers, remove the input shaft bearing (1) from the front case (2). See Fig 1.

Transfer the retaining ring to the new housing, if necessary, and install the bearing into the front case.

Fig 2: Installing Front Output Shaft Bearing

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1 - FRONT CASE

2 - INSTALLER C-4210

3 - HANDLE C-4171

Using Installer 6436 and Handle C-4171, remove front output shaft bearing.

Start front output shaft bearing in case. Then seat bearing with Handle C-4171 (3) and Installer C-4210 (2). See Fig 2.

Fig 3: Installing Rear Output Shaft Bearing

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1 - REAR CASE

2 - REMOVER/INSTALLER 5066

3 - HANDLE C-4171

Remove the rear main shaft bearing retaining ring from inside the rear housing.
Remove the rear output shaft bearing from the rear case using Installer 5066 (2) and Handle C-4171 (3). See Fig 3.
Install the rear output shaft bearing into the rear case using Remover/Installer 8281 (2) and Handle C-4171 (3).
Install the rear output shaft bearing retaining ring into the rear housing, from inside the rear housing.

Fig 4: Removing/Installing Bottom Thrust Washer
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1 - BOTTOM THRUST WASHER (3 TABS)

2 - LOW RANGE PLANETARY
Install the bottom thrust washer (3 tabs) (1) into the low range planetary (2). See Fig 4.

Fig 5: Removing/Installing Top Thrust Washer
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1 - INPUT GEAR

2 - THRUST WASHER (NO TABS)

Install the top thrust washer (no tabs) (2) onto the input gear (1). See Fig 5.

Fig 6: Removing/Installing Low Gear & Lock Plate

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1 - INPUT GEAR

2 - LOCK PLATE

3 - LOW RANGE PLANETARY

Install the input gear (1) and lock plate (2) into the low range planetary (3) and install the lock plate. See Fig 6.

Fig 7: Removing/Installing Low Range Snap-Ring

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1 - INPUT GEAR

2 - SNAP-RING

3 - LOW RANGE PLANETARY

Install the snap-ring (2) to hold the input gear (1) into the low range planetary (3). See Fig 7.

Fig 8: Removing/Installing Input Planetary Assembly
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1 - INPUT GEAR AND LOW RANGE PLANETARY
Install the input gear and low range planetary assembly (1) into the front housing. See Fig 8.

Fig 9: Identifying Input Gear Retaining Ring
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1 - INPUT GEAR

2 - RETAINING RING
Install the retaining ring (2) holding the input gear assembly into the front housing. See Fig 9.
Install the new input shaft seal with Installer 9672 and Handle C-4171.

Fig 10: Removing/Installing Sector Shaft
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1 - FRONT HOUSING

2 - SHIFT SECTOR
Install the shift sector (2) into the rear housing (1). See Fig 10.

Fig 11: Removing/Installing Sector Shaft Retaining Ring
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1 - SHIFT SECTOR

2 - RETAINING RING
Install the retaining ring (2) onto the shift sector shaft (1). See Fig 11.

Fig 12: Removing/Installing Oil Pump Pick-up Tube O-Ring
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1 - REAR HOUSING

2 - O-RING
Install the oil pick-up tube o-ring (2) into the rear housing (1). See Fig 12.

Fig 13: Removing/Installing Oil Pump Pick-up Tube & Screen
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1 - OIL PICK-UP TUBE AND SCREEN
Prime the oil pickup tube by pouring a little oil into the tube before installation.
Install the oil pick-up tube and screen (1) into the rear housing. See Fig 13.

Fig 14: Remove/Install Front Output Shaft and Flange
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1 - FRONT HOUSING

2 - FRONT OUTPUT SHAFT
Install a new front output shaft seal with Installer 6560.
Install the front output shaft (2) into the front housing (1) and the front output shaft front bearing. See Fig 14.

Fig 15: Remove/Install Front Output Shaft Retaining Ring
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1 - FRONT OUTPUT SHAFT

2 - RETAINING RING
Install the retaining ring (2) onto the front output shaft (1). See Fig 15.

Fig 16: Removing/Installing Range Fork & Sleeve
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1 - RANGE FORK

2 - RANGE HUB

NOTE: Check that all three shift pads are present and in good condition on the shift fork.
Install the range fork and range hub as one into the input gear/low range planetary. See Fig 16.

Fig 17: Removing/Installing Retainer at Mode Hub
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1 - MODE HUB

2 - MODE HUB RETAINER
Lubricate mainshaft splines with recommended transmission fluid.
NOTE: Replace the mode hub retainer if the legs were distorted during removal.
Install the mode hub retainer (1) onto the mode hub (2). See Fig 17.

Fig 18: Identifying Mode Hub and Retainer
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1 - DIFFERENTIAL ASSEMBLY

2 - MODE HUB AND RETAINER
Install the mode hub (2) and mode hub retainer onto the differential assembly (1). Make sure the retainer is fully seated onto the differential. See Fig 18.

Fig 19: Identifying Differential
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1 - DIFFERENTIAL ASSEMBLY

2 - MAINSHAFT
Install the differential assembly (1) onto the mainshaft (2). See Fig 19.

Fig 20: Identifying Differential Snap Ring
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1 - DIFFERENTIAL SNAP-RING
Install the differential snap-ring (1). See Fig 20.

Fig 21: Identifying Intermediate Clutch Shaft
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1 - INTERMEDIATE CLUTCH SHAFT
Install the intermediate clutch shaft (1). See Fig 21.

Fig 22: Identifying Intermediate Clutch Shaft Thrust Ring
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1 - CLUTCH SHAFT THRUST RING
Install the clutch shaft thrust ring (1). See Fig 22.

Fig 23: Identifying Intermediate Clutch Shaft Snap Ring
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1 - SNAP-RING

2 - INTERMEDIATE CLUTCH SHAFT
Install clutch shaft (2) snap-ring (1). See Fig 23.

Fig 24: Removing/Installing Mainshaft & Differential Assembly
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1 - MAINSHAFT AND DIFFERENTIAL ASSEMBLY

2 - FRONT HOUSING
Install the mainshaft and differential assembly (1) into the front housing (2), range sleeve, and input gear/low range planetary. See Fig 24.

Fig 25: Removing Chain Guide
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1 - DRIVE CHAIN GUIDE
Install the drive chain guides (1) onto the transfer case. See Fig 25.

Fig 26: Removing/Installing Chain Guide Bolts
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1 - CHAIN GUIDE RAIL

2 - SCREWS

Install the screws (2) to hold the chain guide rails (1) to the front housing. Tighten the screws to 5-8 N.m (44-71 in.lbs.). See Fig 26.

Fig 27: Removing/Installing Front & Rear Drive Sprockets & Drive Chain

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1 - FRONT DRIVE SPROCKET

2 - MAINSHAFT DRIVE SPROCKET

3 - DRIVE CHAIN

Install the front drive sprocket (1), mainshaft drive sprocket (2), and drive chain (3) as one. See Fig 27.

Fig 28: Front Drive Sprocket Retaining Ring Removal/Installation
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1 - FRONT OUTPUT SHAFT

2 - RETAINING RING
Install the front drive sprocket retaining ring (2) onto the front output shaft (1). See Fig 28.

Fig 29: Removing/Installing Clutch Assembly
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1 - OUTPUT SHAFT

2 - CLUTCH ASSEMBLY
Install the clutch assembly (2) onto the main shaft (1). See Fig 29.

Fig 30: Wavy Spring Assembly Removal/Installation
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1 - OUTPUT SHAFT

2 - WAVY SPRING
Install the wave spring (2) onto the main shaft (1). See Fig 30.

Fig 31: Clutch Pressure Plate Removal/Installation
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1 - OUTPUT SHAFT

2 - CLUTCH PRESSURE PLATE

CAUTION: When installing the clutch pressure plate, make sure that the wave spring remains piloted on the underside of the plate. Check that the spring does not protrude between the plate and the mainshaft.
Install the clutch pressure plate (2) onto the main shaft (1) and clutch assembly. See Fig 31.

Fig 32: Thrust Bearing Removal/Installation
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1 - OUTPUT SHAFT

2 - THRUST BEARING
Install the thrust bearing (2) onto the main shaft (1). See Fig 32.

Fig 33: Thrust Bearing Support Plate Removal/Installation
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1 - OUTPUT SHAFT

2 - SUPPORT PLATE
Install the thrust bearing support plate (2) onto the main shaft (1). See Fig 33.

Fig 34: Thrust Bearing Support Plate Retaining Ring Removal/Installation
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1 - OUTPUT SHAFT

2 - RETAINING RING

NOTE: The clutch pressure plate must be engaged with the inner drum and held down when installing the retaining ring.
Install the thrust bearing support plate retaining ring (2) onto the main shaft (1). See Fig 34.

Fig 35: Align Tabs on the Bearing Support Plate
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1 - SUPPORT PLATE

2 - TAB

3 - BOLT HOLES
Rotate the thrust bearing support plate (1) so that the tab (2) is pointed between the two bolt holes (3) as shown. See Fig 35.

Fig 36: Clutch Lever Assembly Removal/Installation
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1 - CLUTCH LEVER ASSEMBLY
Install the clutch lever assembly (1) onto the mainshaft and shift rail. See Fig 36.

Fig 37: Rear Housing Removal/Installation
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1 - REAR HOUSING

2 - FRONT HOUSING
Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of front case. Keep sealer bead width to maximum of 3 mm (0.125 inch). Do not use excessive amount of sealer as excess will be displaced into case interior and potentially clog the oil pump screen.
Verify that the tab on the thrust bearing support plate is aligned with the housing alignment dowel furthest from the front output shaft.

Install the rear housing (1) into the front housing (2). See Fig 37.

Fig 38: Rear Housing Bolts Removal/Installation

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1 - REAR HOUSING

2 - BOLTS

3 - FRONT HOUSING

Install the bolts (2) to hold the rear housing (1) to the front housing (3). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 38.

Fig 39: Rear Output Bearing Inner Retaining Ring Removal/Installation

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1 - OUTPUT SHAFT

2 - RETAINING RING

3 - REAR HOUSING

NOTE: Pull up on the main shaft when installing the retaining ring to ensure that the ring is fully engaged into the groove.

Install the rear main shaft (1) retaining ring (2). See Fig 39.

Fig 40: Oil Pump Outer Rotor Removal/Installation

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1 - OUTPUT SHAFT

2 - OIL PUMP OUTER ROTOR

3 - REAR HOUSING

Lubricate the oil pump components with transmission fluid before installation.

Install the oil pump outer rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 40.

Fig 41: Oil Pump Inner Rotor Removal/Installation

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1 - OUTPUT SHAFT

2 - OIL PUMP INNER ROTOR

3 - REAR HOUSING

Install the oil pump inner rotor (2) onto the main shaft (1) and into the rear housing (3). See Fig 41.

Fig 42: Clutch Lever Rail Removal/Installation
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1 - REAR HOUSING

2 - CLUTCH LEVER RAIL
Install the clutch lever rail (2) into the rear housing (1) and clutch lever. See Fig 42.

Fig 43: Clutch Lever Rail Plug Removal/Installation
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1 - CLUTCH LEVER RAIL PLUG
Install the clutch lever rail plug (1) into the rear housing. See Fig 43.

Fig 44: Anti-Rotation Bracket Removal/Installation
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1 - ANTI-ROTATION BRACKET

2 - SHIFT RAIL
Install the anti-rotation bracket (1) onto the shift rail (2). See Fig 44.

Fig 45: Sector Roller Removal/Installation
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1 - SECTOR ROLLER

2 - SHIFT RAIL
Install the sector roller (1) onto the shift rail (2). See Fig 45.
Using a suitable punch, align the holes in the sector roller with the hole in the shift rail and install the roll-pin to secure the sector roller to the shift rail.

Fig 46: Sealant Application Pattern
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1 - REAR HOUSING

2 - SEALANT
Apply bead of Mopar® Gasket Maker, or equivalent, to mating surface of rear housing as shown (2). See Fig 46. Keep sealer bead width to maximum of 3 mm (1/8 inch). Do not use excessive amount of sealer as excess could be displaced into the oil pump.

Fig 47: Rear Retainer Removal/Installation
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1 - REAR COVER

2 - REAR HOUSING
Install a new rear output shaft seal into the rear cover with Installer C-3972A.
Install the rear cover (1) onto the rear housing (2). See Fig 47.

Fig 48: Rear Retainer Bolts Removal/Installation
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1 - REAR HOUSING

2 - REAR COVER

3 - BOLTS
Install the bolts (3) holding the rear cover (2) onto the rear housing (1). Tighten the bolts at the dowel locations first, then the remainder of the bolts in a criss-cross pattern. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 48.

Fig 49: Shift Motor Drive Splines
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Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.

Fig 50: Transfer Case Drive Splines

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NOTE: Verify that the missing tooth (2) in the shift motor drive spline (1) and the transfer case drive spline (1) missing tooth (2) are aligned. It may be necessary to manually shift the transfer case if the shift motor and transfer case shaft are not aligned.

Fig 51: Shift Motor Removal/Installation

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1 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY

2 - SHIFT SECTOR

3 - TRANSFER CASE

Install the shift motor and mode sensor assembly (1) onto the shift sector (2) and the transfer case (3). See Fig 51.

Fig 52: Shift Motor Bolts Removal/Installation
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1 - BOLTS

2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY
Install the bolts (1) to hold the shift motor and mode sensor assembly (2) to the transfer case. Tighten the bolts to 27 N.m (20 ft.lbs.). See Fig 52.

Fig 53: Rear Output Shaft Flange Removal/Installation
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1 - REAR COMPANION FLANGE

2 - OUTPUT SHAFT
If necessary, install the transfer case damper onto the transfer case.
Install the rear output flange (1) onto the main shaft (2). See Fig 53.

Fig 54: Rear Output Shaft Nut Removal/Installation
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1 - HOLDER C-3281

2 - REAR COMPANION FLANGE
Using Holder C-3281 (1), install the rear output flange (2) nut. Tighten the bolts to 122-176 N.m (90-130 ft.lbs.). See Figure.