Jeep XJ. Manual — part 457
MAINSHAFT ASSEMBLY
(1) Lubricate mainshaft splines with recommended
transmission fluid.
(2) Slide drive sprocket onto mainshaft.
(3) Slide mode hub onto mainshaft.
(4) Install mode hub retaining ring. Verify that the
retaining ring is fully seated in mainshaft groove.
SHIFT FORKS AND MAINSHAFT INSTALLATION
(1) Install new sector shaft O-ring and bushing
(Fig. 60).
(2) Install shift sector in case (Fig. 61). Lubricate
sector shaft with transmission fluid before installa-
tion.
(3) Install range lever, washer, and nut on sector
shaft (Fig. 62). Tighten range lever nut to 27–34 N.m
(20–25 ft. lbs.) torque.
(4) Assemble and install range fork and hub (Fig.
63). Be sure hub is properly seated in low range gear
and engaged to the input gear.
(5) Align and insert range fork pin in shift sector
slot.
(6) Install assembled mainshaft (Fig. 64). Be sure
shaft is seated in pilot bearing and input gear.
(7) Install new pads on mode fork if necessary.
Fig. 57 Input/Low Range Gear Installation
1 – ANNULUS GEAR
2 – INPUT/LOW RANGE GEAR
Fig. 58 Install Snap-Ring
1 – INPUT GEAR
2 – SNAP RING
Fig. 59 Install Front Bearing Retainer
1 – FRONT BEARING RETAINER
Fig. 60 Sector O-Ring And Bushing Installation
1 – SECTOR BUSHING
2 – O-RING
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DISASSEMBLY AND ASSEMBLY (Continued)
(8) Insert mode sleeve in mode fork mode fork. Be
sure long side of sleeve is toward long end of shift
rail (Fig. 65).
(9) Install assembled mode fork and sleeve (Fig.
66). Be sure fork rail goes through range fork and
into case bore. Also be sure sleeve is aligned and
seated on mainshaft hub.
(10) Rotate sector to Neutral position.
(11) Install new O-ring on detent plug (Fig. 67).
(12) Lubricate detent plunger with transmission
fluid or light coat of petroleum jelly.
(13) Install detent plunger, spring and plug (Fig.
67).
(14) Verify that plunger is properly engaged in sec-
tor.
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Lubricate front output shaft-sprocket assembly,
drive chain, and drive sprocket with transmission
fluid.
Fig. 61 Shift Sector Installation
1 – SHIFT SECTOR
Fig. 62 Range Lever Installation
1 – RANGE LEVER
2 – LEVER NUT
Fig. 63 Install Range Fork And Hub Assembly
1 – RANGE HUB
2 – RANGE FORK
Fig. 64 Mainshaft Assembly Installation
1 – DRIVE SPROCKET
2 – MODE HUB
3 – MAINSHAFT
Fig. 65 Assembling Mode Fork And Sleeve
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
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NV231 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(2) Assemble drive chain and front output shaft
(Fig. 68).
(3) Start chain on mainshaft drive sprocket.
(4) Guide front shaft into bearing and drive
sprocket onto mainshaft drive gear (Fig. 68).
(5) Install mode spring on upper end of mode fork
shift rail (Fig. 69).
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
(1) Install magnet in front case pocket (Fig. 70).
(2) Assemble oil pickup screen, connecting hose,
and tube.
(3) Install new pickup tube O-ring in oil pump
(Fig. 71).
(4) Insert oil pickup tube in oil pump inlet.
(5) Position assembled oil pump and pickup tube
in rear case. Be sure pickup screen is securely seated
in case slot. Also be sure oil pump locating tabs are
outside rear case (Fig. 72).
(6) Apply 3 mm (1/8 in.) wide bead of Mopar
t gas-
ket maker or silicone adhesive sealer to mounting
Fig. 66 Mode Fork And Sleeve Installation
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
Fig. 67 Shift Detent Components
1 – POPPET
2 – SPRING
3 – SCREW
4 – POPPET BORE (IN CASE)
Fig. 68 Installing Drive Chain And Front Output
Shaft
1 – FRONT OUTPUT SHAFT
2 – DRIVE CHAIN
3 – MAINSHAFT
4 – DRIVE SPROCKET
Fig. 69 Install Mode Fork Spring
1 – MODE SPRING
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DISASSEMBLY AND ASSEMBLY (Continued)
flange of front case. Work sealer bead around bolt
holes.
(7) Lift rear case and oil pump and carefully posi-
tion assembly on front case. Be sure case dowels are
aligned and that mode fork rail extends through rear
case before seating rear case on front case.
(8) Install case attaching bolts. Alignment bolts at
each end of case are only ones requiring washers
(Fig. 73).
(9) Tighten case bolts to 27-34 N·m (20-25 ft. lbs.)
torque.
YOKE AND RANGE LEVER INSTALLATION
(1) Install indicator switch in front case. Tighten
switch to 20–34 N·m (15–25 ft. lbs.) torque.
(2) Install range lever, washer and locknut on sec-
tor shaft (Fig. 74). Tighten locknut to 27-34 N·m
(20-25 ft. lbs.) torque.
(3) Install new seal washer on front output shaft
(Fig. 76).
(4) Lubricate yoke hub with transmission fluid and
install yoke on front shaft.
(5) Install new seal washer on front shaft.
(6) Install yoke and new yoke nut on front output
shaft (Fig. 75).
(7) Tighten yoke nut to 122-176 N·m (90-130 ft.
lbs.) torque. Use Tool C-3281, or similar tool to hold
yoke while tightening yoke nut.
REAR RETAINER INSTALLATION
(1) Apply bead of Mopar
t Sealer P/N 82300234, or
Loctite
y Ultra Gray, to mating surface of rear
retainer. Sealer bead should be a maximum of 3/16
inch.
(2) Install rear retainer on rear case. Tighten
retainer bolts to 20–27 N·m (15–20 ft. lbs.) torque.
(3) Install rear bearing I. D. retaining ring and
spacer on output shaft.
Fig. 70 Installing Case Magnet
1 – MAGNET
Fig. 71 Pickup Tube O-Ring Position
1 – OIL PUMP
2 – O-RING
Fig. 72 Oil Pump And Pickup Tube Installation
1 – OIL PUMP
2 – PICKUP TUBE
3 – PICKUP SCREEN AND CONNECTOR
Fig. 73 Alignment Bolt Location
1 – ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
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DISASSEMBLY AND ASSEMBLY (Continued)
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