2500 4x4 Pickup V8-360 5.9L VIN 5 Magnum (1994)
Synchronizer Hub: All Technical Service Bulletins
Transfer Case - High Shift Effort When Cold
NO.: 21-25-94
GROUP: Transmission
DATE: Dec. 23, 1994
SUBJECT:
High Effort when Shifting from 2WD High to 4WD High, in Cold Ambient Temperatures
MODELS:
1994 - 1995 (BR) Ram Truck
NOTE:
THIS BULLETIN APPLIES TO BR VEHICLES EQUIPPED WITH NP231 HD, NP241, OR NP241 HD TRANSFER CASE.
SYMPTOM/CONDITION:
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 may 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 mode for approximately 10 miles. Shift transfer case from 2WD High to 4WD High several
times. Allow time between shifts to ensure synchronizer is out of the 4WD High mode before shifting.
NOTE:
AVOID SHARP TURNS ON HARD DRY SURFACES WHILE TESTING 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.
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 REQUIRED:
