NV241HD Transfer Case

1. Remove vacuum indicator switch.





2. Loosen poppet plunger screw.





3. Remove poppet plunger screw and spring. Note that screw has O-ring seal. Remove and discard seal this seal.





4. Remove poppet plunger with magnet.





5. Remove front output shaft from bearing in case.





6. Pull mainshaft assembly out of input gear, sliding clutch and case.





7. Remove mode fork, sliding clutch and shift rail as assembly. Note which way clutch fits in fork (long side of clutch goes to front).





8. Remove range fork retaining ring.





9. Remove range fork and support sleeve as assembly.





10. Remove shift sector.





11. Remove shift sector shaft nylon retainer and O-ring from shaft bore in front case.