NV241HD Transfer Case

1. Using Remover C-4210 and Handle C-4171, or equivalents, drive input shaft bearing from case from inside annulus gear opening.
2. Install locating ring on new bearing.
3. Position case so that the forward end is facing upward.





4. Using Remover C-4210 and Handle C-4171, or equivalents, drive input shaft bearing into case. The bearing locating ring must be fully seated on case.
5. Using Installer 6953, or equivalent, remove front output shaft bearing.





6. Start front shaft output bearing in case. Then seat bearing with Handle C-4171 and Installer 6953, or equivalents.
7. Install front output bearing retaining ring.
8. Install new front output seal in front case with Installer Tool 6888 and Tool Handle C-4171, or equivalents as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.





b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool bottoms against case.





c. Remove installer and verify that seal is recessed the proper amount. Seal should be 2.03 to 2.5 mm (0.080 to 0.100 inch) below top edge of seal bore in front case. This is correct final seal position.

CAUTION: Be sure the front output seal is seated below the top edge of the case bore as shown. The seal could loosen, or become cocked if not seated to recommended depth.

9. Remove seal from front bearing retainer with suitable pry tool.





10. Install new oil seal in front bearing retainer with Installer 7884, or equivalent.
11. Remove seal from oil pump with suitable pry tool.





12. Install new seal in oil pump with Installer 7888, or equivalent.





13. Inspect carrier needle bearing. If bearing is worn, rough, or damaged in any way, remove it with a brass punch and hammer.





14. Install new needle bearing in planetary carrier. Use Handle C-4171 and Installer 5062, or equivalents to install bearing.





15. Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer.
16. Install new pilot bearing with Plug C-293-3, or equivalent.





17. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148, or equivalents.








18. Install new bearing with Tool Handle C-4171 and Installer 5066, or equivalents. The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer.