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TSB 21-25-94

High Effort when Shifting from 2WD High to 4WD High,
in Cold Ambient Temperatures

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Date: Dec. 23, 1994

Models: 1994 - 1995 (BR) Ram Truck

NOTE: This bulletin applies to BR vehicles equipped with NP231 HD, NP 241, or NP241 HD transfer case.

Symptoms:

High shift effort, condition occurs during cold weather operation while shifting the transfer case into 4WD High from the 2WD High mode.

Diagnosis: 

With vehicle cold (below 30 degrees F), shift transfer case from 2WD High to 4WD High with the vehicle stationary. It way be necessary to move vehicle slightly forward or rearward to engage front axle.

If transfer case does not shift with the vehicle stationary, check external shift linkage for proper adjustment. Reference appropriate Ram Truck Service Manual for transfer case shift linkage adjustment procedure.

With vehicle still cold, attempt to shift from 2WD High to 4WD High at approximately 25 MPH. While shifting, apply a constant force to the transfer case shift lever, not a quick pull. This will allow the synchronizer time to get the front propshaft up to speed. With cold front axle lubricant, the vehicle may require high effort for an extended time, or will not shift.

Warm front axle lubricant by operating vehicle in 4WD High nude for approximately 10 miles. Shift transfer case from 2WD High to 4WD High several Allow tire between shifts to ensure synchronizer is out of the 4WD High nude before shifting.

NOTE: Avoid sharp turns on hard dry surfaces while testing the vehicle.

If vehicle exhibits high shifting effort in cold weather operation (below 30 degrees F), but has reasonable effort and consistency after axle lube is warm, perform the front axle lubricant fill procedure listed below.

If Vehicle requires high shifting effort and shifts inconsistently after the front axle lubricant is warm, the following transfer case parts require replacement in addition to the front axle lubricant change.

Parts: 

Front Axle lubricant
AR 4467707 Mopar High Performance Synthetic Axle Lube (amount specified below by transfer case.)

241 SD Transfer Case

1   4746256 Drive Sprocket
1   4746143 Synchronizer Hub
1   4746144 Synchronizer Sleeve
3   4746137 Synchronizer Strut
2   4746138 Synchronizer Strut Spring
1   4746139 Synchronizer Stop Ring  

241 HD Transfer Case

1   4746142 Drive Sprocket
1   4746143 Synchronizer Hub
1   4746144 Synchronizer Sleeve
3   4746137 Synchronizer Strut
2   4746138 Synchronizer Strut Spring
1   4746139 Synchronizer Stop Ring

231 HD Transfer Case

1   4746265 Drive Sprocket
1   4746143 Synchronizer Hub
1   4746144 Synchronizer Sleeve
3   4746137 Synchronizer Strut
2   4746138 Synchronizer Strut Spring
1   4746139 Synchronizer Stop Ring

Repair: 

This bulletin involves replacing the lubricant in the front axle, and in sane cases, replacing the above listed parts in the transfer case.

FRONT AXLE LUBRICANT REPLACEMENT

1. Using a suction pump, remove as much axle lubricant as possible.

NOTE: It is not necessary to remove the front differential cover.

2. Refill the axle with Mopar High Performance Synthetic Axle Lube as specified below.

BR Truck - 44F Axle Fill to within 1/4" of the bottom of the fill plug hole (approximately 77 ounces).

BR Truck - 60F Axle Fill to within 1/2" of the bottom of the fill plug hole (approximately 122 ounces).

NOTE: Overfill can result in lubricant "foaming" and/or unit overheating.

TRANSFER CASE COMPONENT REPLACEMENT

1. After completing the above front axle lubricant change, test the shifting effort.

2. If high shifting effort or inconsistent shifting is occurring, replace the synchronizer assembly referencing Group 21 in the appropriate Service Manual.

Notes: 

Policy:    Reimbursable within the provisions of the warranty.

Time Allowance:
Labor Operation No:  21-03-01-93 (Fluid, Front Axle-Replace, 1994-1994 3 Hrs.
                                  21-03-01-94 (Synchronizer, Replace, 1994-1995) 2.1 Hrs.

                                  Optional equipment
                                  21-03-01-60 (Skid Plate equipped, 1994-1995) . 0.4 Hrs.

Failure Code:  P8 - New Part 


Thanks to Bob Bergevin and Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004