Dodge Dakota (R1). Manual - part 728

(8) Install assembled mode fork and sleeve (Fig.

60). Be sure fork rail goes through range fork and
into case bore. Also be sure sleeve is aligned and
seated on mainshaft hub.

(9) Rotate sector to NEUTRAL position.
(10) Install new O-ring on detent plug (Fig. 61).
(11) Lubricate detent plunger with transmission

fluid or light coat of petroleum jelly.

(12) Install detent plunger, spring and plug (Fig.

61).

(13) Verify that plunger is properly engaged in sec-

tor.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

(1) Lubricate front output shaft-sprocket assembly,

drive chain and drive sprocket with transmission fluid.

(2) Assemble drive chain and front output shaft

(Fig. 62).

(3) Start chain on mainshaft drive sprocket.
(4) Guide front shaft into bearing and drive

sprocket onto mainshaft drive gear (Fig. 62).

(5) Install mode spring on upper end of mode fork

shift rail (Fig. 63).

Fig. 60 Mode Fork And Sleeve Installation

1 - MODE SLEEVE
2 - MODE FORK AND RAIL

Fig. 61 Shift Detent Components

1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING

Fig. 62 Installing Drive Chain And Front Output Shaft

1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE SPROCKET

Fig. 63 Install Mode Fork Spring

1 - MODE SPRING

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TRANSFER CASE - NV233

TRANSFER CASE - NV233 (Continued)

OIL PUMP AND REAR CASE

(1) Install magnet in front case pocket (Fig. 64).
(2) Assemble oil pickup screen, connecting hose,

and tube.

(3) Install new pickup tube O-ring in oil pump

(Fig. 65).

(4) Insert oil pickup tube in oil pump inlet.
(5) Position assembled oil pump and pickup tube

in rear case. Be sure pickup screen is securely seated
in case slot. Also be sure oil pump locating tabs are
outside rear case (Fig. 66).

(6) Apply 3 mm (1/8 in.) wide bead of Mopar® Gas-

ket Maker, or equivalent silicone adhesive sealer, to
mounting flange of front case. Work sealer bead
around bolt holes.

(7) Lift rear case and oil pump and carefully posi-

tion assembly on front case. Be sure case dowels are
aligned and that mode fork rail extends through rear
case before seating rear case on front case.

(8) Install case attaching bolts. Alignment bolts at

each end of case are only ones requiring washers
(Fig. 67).

(9) Tighten case bolts to 27-34 N·m (20-25 ft. lbs.)

torque.

COMPANION FLANGE AND SHIFT MOTOR AND
MODE SENSOR ASSEMBLY

(1) Position the shift motor and mode sensor

assembly onto the transfer case.

(2) Install the bolts to hold the shift motor and

mode sensor assembly to the transfer case. Tighten
the bolts to 16-25 N·m (12-18 ft. lbs.) torque.

Fig. 64 Installing Case Magnet

1 - MAGNET

Fig. 65 Pickup Tube O-Ring Position

1 - OIL PUMP
2 - O-RING

Fig. 66 Oil Pump And Pickup Tube Installation

1 - OIL PUMP
2 - PICKUP TUBE
3 - PICKUP SCREEN AND CONNECTOR

Fig. 67 Alignment Bolt Location

1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)

TRANSFER CASE - NV233

21 - 557

TRANSFER CASE - NV233 (Continued)

CAUTION: If the original shift motor and mode sen-
sor assembly bolts are reused, be sure to use
Mopar® Lock & Seal or Loctite™ 242 to replenish
the lock patch material originally found on the bolts

(3) Install new seal washer onto the front output

shaft (Fig. 68).

(4) Lubricate

the

companion

flange

hub

with

transmission fluid and install the flange onto the
front output shaft.

(5) Install a new companion flange nut onto the

front output shaft.

(6) Tighten the flange nut to 122-176 N·m (90-130

ft. lbs.) torque. Use Tool 6958, or similar tool to hold
flange while tightening nut.

REAR RETAINER

(1) Apply 3 mm (1/8 in.) wide bead of Mopar® Gas-

ket Maker, or equivalent silicone adhesive sealer, to
mounting surface of rear retainer. Allow sealer to
set-up slightly before proceeding.

(2) Install rear retainer on rear case. Tighten

retainer bolts to 27-34 N·m (20-25 ft. lbs.).

(3) Install new output shaft bearing snap-ring

(Fig. 69). Lift mainshaft slightly to seat snap-ring in
shaft groove, if necessary.

(4) Apply 3 mm (1/8 in.) wide bead of Mopar® Gas-

ket Maker, or equivalent silicone adhesive sealer, to
mounting surface of extension housing. Allow sealer
to set-up slightly before proceeding.

(5) Install extension housing on rear retainer.

(6) Install extension housing bolts and tighten to

27-34 N·m (20-25 ft. lbs.).

INSTALLATION

(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts

and install transfer case onto the transmission.

(5) Install and tighten transfer case attaching nuts

to 27-34 N·m (20-25 ft. lbs.) torque.

(6) Connect the vent hose.
(7) Connect the shift motor and mode sensor wir-

ing connectors. Secure wire harness to clips on trans-
fer case.

(8) Align and connect the propeller shafts.
(9) Fill transfer case with correct fluid. (Refer to

TRANSMISSION/TRANSAXLE/TRANSFER

CASE/FLUID - STANDARD PROCEDURE)

(10) Install rear crossmember and skid plate, if

equipped. Tighten crossmember bolts to 41 N·m (30
ft. lbs.) torque.

(11) Remove transmission jack and support stand.
(12) Lower vehicle and verify transfer case shift

operation.

Fig. 68 Yoke Seal Washer Installation

1 - YOKE SEAL WASHER

Fig. 69 Install Output Bearing Snap-Ring

1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING

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TRANSFER CASE - NV233

TRANSFER CASE - NV233 (Continued)

SPECIFICATIONS

SPECIFICATIONS - TRANSFER CASE - NV233

TORQUE SPECIFICATIONS

DESCRIPTION

N-m

Ft. Lbs.

In. Lbs.

Plug, Detent

16-24

12-18

Plug, Drain/Fill

20-34

15-25

Bolt, Front Brg. Retainer

16-25

12-18

Bolt, Case Half

27-34

20-25

Nut, Companion Flange

122-176

90-130

Bolt, Shift motor and

Mode Sensor Assembly

16-25

12-18

Bolt, Rear Retainer

27-34

20-25

Bolt, Extension Housing

27-34

20-25

Nut, Mounting

27-34

20-25

SPECIAL TOOLS

TRANSFER CASE - NV233

Installer, Seal - 8143-A

Remover, Bushing - 8158

Installer, Bushing - 8157

Installer, Seal - D-163

Handle, Universal - C-4171

TRANSFER CASE - NV233

21 - 559

TRANSFER CASE - NV233 (Continued)

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