Mopar R3008208 Transfer Case Assembly, Model Npg 231

A do-it-yourselfer can spend a lot of time with an overhaul of a transfer case in the way, that it demands great attention to detail when packing with many small parts taken apart and reassembled with precise clearances to be adjusted with select fit spacers and snap-rings. Although any capable mechanic can replace a transfer case or remove and install an overhaul assembly, an overhaul is typically done from a transmission repair shop since the time and cost is usually more than that of getting a rebuilt assembly which is available from dealer parts departments or from auto parts stores. What a novice mechanic can do is, given that special tools and proper instructions accompanied by a checklist to be sure that no step was missed during the rebuild procedure. As is the case in most automobile industries, basic tools that are necessary for the job may include internal and external snap ring pliers, bearing puller, slide hammer, a set of pin punches, a dial indicator and in some cases a hydraulic press, a strong working table, a vise or transmission stand. In disassembly, one should make sketches regarding the position and interconnection of certain components besides what holds them together while the explosion view can help to explain the assembly. At least it provides knowledge of which area of the transfer case is not functioning correctly to examine and replace the components; some problems are associated with certain locations.

To replace the transfer case, first shut down the car and loosen the negative terminal of the battery and then jack up the car and set it on jackstands. Remove the transfer case oil, then uninstall the following items: speedometer cable, shift lever, vacuum/vent and wire harness connectors. Drive shafts and sections of the exhaust system that may interfere must be taken out. Place some support under the car in line with the transmission with a jack or a jackstand so that the car will remain on it as the transfer case comes out or not. Positive fix by screw-jack, better if it has a special two-post for it and fix it with safety chains on transfer case. Swapping of the crossmember and removal of the rear transmission support-to-crossmember nut as well as the bolts and the crossmember bolts is done. Lift the transfer case up a little to take the crossmember out and then lower the transmission to reveal the upper nuts that attach the transfer case. Once all wiring and hydraulic hoses have been disconnected verify this and then position the transfer case shift lever towards the rear of the vehicle and the jack till you are out of contact with the transmission while maintaining level. After the slotter has pushed the input shaft out of gear, lower the transfer case and remove it from under the car. In installation, first clamp the transfer case on the jack and lift it into position resting behind the transmission, and then gently push the transfer case forward until the input shaft mashes with the transmission output shaft but not with much force. Tighten the nuts of the transmission-to-transfer case and then tighten the nuts to the required torque value After this crossmember along withe transmission support is properly fixed and all bolts in position tightened. Take out the jacks that where supporting the transmission and transfer case back in all the different items that was removed before, check that the wires, hose and the speedometer cable are well connected, ensure that the transmission is covered with some lubricant to reach the correct level with it before lowering the vehicle. Lastly, attach the negative battery cable back and perform a road-test test to confirm functionality of the system, and also for signs of leakage.