Chrysler Full-Size Trucks 1989-1996 Repair Guide

Adjustments

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LINKAGE



New Process 205
  1. Shift the transfer case into Neutral.
  2.  
  3. Move the shift rod boot upward for access.
  4.  
  5. Loosen the shift bracket bolts and move the bracket as far forward as possible. Tighten the bolts.
  6.  
  7. Check the smoothness of operation of the transfer case.
  8.  

New Process 231 and 241 See Figures 1 and 2

This procedure is identical for all years except that earlier models (1989-93) require a different shift position than the later models (1994-96) when performing the standard adjustment procedure.

  1. Move the transfer case shift lever boot aside for access to the shift lever and gate.
  2.  
  3. On 1989-93 models, move the shift lever into the 4H position. Make sure the lever is against the 4H gate.
  4.  
  5. On 1994-96 models, move the shift lever into the 2H position. Make sure the lever is against the 2H gate.
  6.  
  7. Raise the vehicle and support safely.
  8.  
  9. Loosen the shift rod clamp screw until the shift rod is free to slide in the swivel.
  10.  
  11. Verify that the lever is in the 4H (1989-93 models) or 2H (1994-96 models) position and move it if it has moved out of position.
  12.  
  13. Tighten the lock bolt to 90 inch lbs. (10 Nm).
  14.  
  15. Lower the vehicle.
  16.  
  17. Check the smoothness of operation of the transfer case.
  18.  



Click image to see an enlarged view

Fig. Fig. 1: Shift linkage adjustment procedure and exploded view of the NP-241 shift linkage



Click image to see an enlarged view

Fig. Fig. 2: Details of the NP-231 transfer case shifter mechanism

 
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