Transfer Case Fluid Change

This procedure drains and refills the NV241 or NV271 transfer case with fresh ATF+4 fluid to maintain proper lubrication and shifting performance.

Warnings

Tools required

Parts

• Transfer case drain plug washer (if damaged) × 1 — OEM or aftermarket copper washer
• Transfer case fill plug washer (if damaged) × 1 — OEM or aftermarket copper washer

Fluids

• Mopar ATF+4 — 4.5 qt

Preparation

1. Park vehicle on level ground and engage parking brake
2. Place wheel chocks behind rear tires
3. If recently driven, allow transfer case to cool for at least 30 minutes
4. Raise front of vehicle with jack and support securely on jack stands at frame rails
5. Verify vehicle is stable and level before working underneath
6. Locate transfer case on passenger side of transmission - identify drain plug on bottom and fill plug on rear/side of case

Procedure

1. 1

   Remove fill plug first
   Using a 3/8 inch ratchet and appropriate socket, loosen and remove the fill plug from the rear/side of the transfer case. This plug must be removed first to ensure you can refill the case after draining. If plug is stuck or rounded, do not proceed until it can be safely removed.
2. 2

   Position drain pan
   Place drain pan beneath transfer case drain plug location on bottom of case. Ensure pan has adequate capacity for approximately 2 quarts of fluid and is positioned to catch fluid flow.
3. 3

   Remove drain plug and drain fluid
   Using appropriate socket, carefully loosen the drain plug. Once loose, quickly remove by hand while avoiding the draining fluid. Allow transfer case to drain completely until flow stops, typically 5-10 minutes. Inspect drained fluid for metal shavings or debris indicating potential internal wear.
4. 4

   Clean and inspect drain plug
   Clean drain plug threads and sealing surface with shop rag or wire brush. Inspect crush washer or sealing surface for damage. Replace washer if cracked, heavily compressed, or damaged. Clean drain plug hole threads on transfer case.
5. 5

   Install drain plug
   Install drain plug with washer into transfer case. Thread by hand first to avoid cross-threading. Tighten to specification using torque wrench.
   Torque spec

   Transfer Case Drain Plug25 Nm (18 lb-ft)
6. 6

   Fill transfer case with ATF+4
   Using fluid transfer pump, insert pump nozzle into fill plug hole. Slowly pump Mopar ATF+4 fluid into transfer case until fluid begins to drip from fill hole, indicating proper level. This will require approximately 2 quarts. Allow fluid to settle for 1-2 minutes and top off if needed.
7. 7

   Clean and inspect fill plug
   Clean fill plug threads and sealing surface. Inspect washer for damage and replace if necessary. Wipe away any spilled fluid from transfer case exterior.
8. 8

   Install fill plug
   Install fill plug with washer into transfer case. Thread by hand first to avoid cross-threading. Tighten to specification using torque wrench.
   Torque spec

   Transfer Case Fill Plug25 Nm (18 lb-ft)
9. 9

   Lower vehicle and clean up
   Remove drain pan from under vehicle. Lower vehicle from jack stands safely. Dispose of used ATF+4 fluid properly at recycling center or automotive shop.

Reassembly

1. Ensure both drain and fill plugs are torqued to specification
2. Verify no fluid leaks are present around plug areas
3. Wipe down transfer case exterior to identify any future leaks

Verification

• Start engine and shift transfer case through all positions (2H, 4H, N, 4L) while stationary
• Check for leaks around drain and fill plugs with engine running
• Test drive vehicle in 2WD and 4WD modes to verify proper transfer case operation and smooth shifting
• Re-check fill and drain plugs for leaks after test drive

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