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><title
>DIAGNOSIS AND TESTING - TRANSFER CASE - NV241 GENII</title><para
><ptxt
>Before beginning repair on a suspected transfer case malfunction, check all other driveline components beforehand.</ptxt></para><para
><ptxt
>The actual cause of a problem may be related to such items as: front hubs, axles, propeller shafts, wheels and tires, transmission, or clutch instead. If all other driveline components are in
good condition and operating properly, refer to the Diagnosis Chart for further information.</ptxt></para><table
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><title
><emph
>DIAGNOSIS CHART</emph></title><tgroup
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><entry
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><ptxt
>Condition</ptxt></entry><entry
valign="top"
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><ptxt
>Possible Cause</ptxt></entry><entry
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><ptxt
>Correction</ptxt></entry></row></thead><tbody
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><entry
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><ptxt
>Transfer Case difficult to shift or will not shift into desired range.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Vehicle speed too great to permit shifting.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Stop vehicle and shift into desired range. Or, reduce speed to below 3-4 km/h (2-3 mph) before attempting the shift.</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>2) If vehicle was operated for an extended period in 4H on a dry paved surface, the driveline torque load may be causing a bind.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>2) Stop vehicle and shift the transmission into neutral. Shift the transfer case to 2H and operate vehicle in 2H on dry paved surfaces.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>3) Transfer case external shift linkage binding.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>3) Lubricate, repair, or replace linkage bushings, or tighten loose components as necessary.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>4) Insufficient or incorrect lubricant.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>4) Drain and refill to edge of fill hole with Mopar® ATF +4, Automatic Transmission fluid.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>5) Internal components binding, worn, or damaged.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>5) Disassemble the transfer case and replace worn or damaged components as necessary.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>Transfer Case noisy in all operating ranges.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Insufficient or incorrect lubricant.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Drain and refill to edge of fill hole with Mopar® ATF +4, Automatic Transmission fluid.</ptxt></entry></row><row
><entry
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><ptxt
>Noisy in, or jumps out of, four wheel drive low range.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Transfer case not completely engaged in 4L position.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) With the transmission in NEUTRAL, or the clutch depressed in the case of a manual transmission and the vehicle moving under 3-4 km/h (2-3 mph), shift the transfer
case to NEUTRAL and then shift into the 4L position.</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>2) Shift linkage out of adjustment.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>2) Adjust linkage.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>3) Shift linkage loose or binding.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>3) Tighten, lubricate, or repair linkage as necessary.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>4) Range fork damaged, inserts worn, or fork is binding on the shift rail.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>4) Disassemble unit and repair as necessary.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>5) Low range gear worn or damaged.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>5) Disassemble unit and repair as necessary.</ptxt></entry><entry
></entry></row><row
><entry
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><ptxt
>Lubricant leaking from output shaft seal or vent.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Transfer case overfilled.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Drain lubricant to the correct level.</ptxt></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>2) Vent closed or restricted.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>2) Clear or replace vent as necessary.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>3) Output shaft seals damaged or installed incorrectly.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>3) Replace seal as necessary. Check to ensure that another component, the propeller shaft slip yoke for example, is not causing damage to seal.</ptxt></entry><entry
></entry></row><row
><entry
valign="top"
align="left"
><ptxt
>Abnormal tire wear.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Extended operation on hard, dry surfaces in the 4H position.</ptxt></entry><entry
valign="top"
align="left"
><ptxt
>1) Operate vehicle in the 2H position on hard, dry surfaces.</ptxt></entry></row></tbody></tgroup></table></servinfo>