Jeep XJ. Manual — part 453
Condition
Possible Cause
Correction
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Repair or replace components as
necessary.
5) Low range gear worn or
damaged.
5) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled.
1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear.
1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember, or skid plate.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires.
(9) Disconnect transfer case linkage rod from
range lever.
(10) Disconnect transfer case vent hose (Fig. 3)
and indicator switch harness, if necessary.
(11) Support transfer case with transmission jack.
(12) Secure transfer case to jack with chains.
(13) Remove nuts attaching transfer case to trans-
mission.
(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N·m (26 ft. lbs.) torque (Fig. 3).
(6) Connect vehicle speed sensor wires, and vent
hose.
(7) Connect indicator switch harness to transfer
case switch, if necessary. Secure wire harness to clips
on transfer case.
Fig. 3 Transfer Case Mounting
1 – VENT TUBE
2 – TRANSFER CASE
3 – TRANSMISSION
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NV231 TRANSFER CASE
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DIAGNOSIS AND TESTING (Continued)
(8) Align and connect propeller shafts. Refer to
Group 3, Differential and Driveline, for proper proce-
dures and specifications.
(9) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(10) Install
rear
crossmember,
or
skid
plate.
Tighten crossmember bolts to 41 N·m (30 ft. lbs.)
torque.
(11) Remove transmission jack and support stand.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage.
(14) Lower vehicle and verify transfer case shift
operation.
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to Group 23, Body, for
proper procedures.
(6) Remove screws attaching lever assembly to
floorpan and remove assembly and shift rod (if left
attached).
INSTALLATION
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install
assembly attaching screws.
(2) Install console. Refer to Group 23, Body, for
proper procedures.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever. Be sure shift
rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then
tighten trunnion lock bolt.
Fig. 4 Shift Linkage
1 – RIVNUT (4)
2 – SHIFT LEVER ASSEMBLY
3 – FLOORPAN
4 – TRUNNION LOCK BOLT
5 – SELECTOR ROD AND TRUNNION
6 – SHIFT LEVER ROD
7 – TORQUE SHAFT FRAME BRACKET
8 – TORQUE SHAFT
9 – TRANSFER CASE SHIFT LEVER
10 – TORQUE SHAFT TRANSFER CASE BRACKET
TORQUE
A
3-4 N
•
m (27-35 in. lbs.)
B
11-14 N
•
m (97-123 in. lbs.)
C
8-14 N
•
m (72-120 in. lbs.)
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NV231 TRANSFER CASE
21 - 349
REMOVAL AND INSTALLATION (Continued)
(6) Lower vehicle and check transfer case shift
operation.
SPEEDOMETER
REMOVAL
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 5).
(4) Remove speed sensor and speedometer adapter
as an assembly.
(5) Remove speed sensor retaining screw and
remove sensor from adapter.
(6) Remove
speedometer
pinion
from
adapter.
Replace pinion if chipped, cracked, or worn.
(7) Inspect sensor and adapter O-rings (Fig. 5).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in speed sensor. Clean
pins with Mopar
t electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or if pins are loose,
severely corroded, or damaged.
INSTALLATION AND INDEXING
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter (Fig. 5), if necessary.
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N·m
(15-27 in. lbs.) torque.
(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 6).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until required range numbers
are at 6 o-clock position. Be sure range index num-
bers correspond to number of teeth on pinion gear.
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 N·m (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Raise vehicle.
(2) Remove front propeller shaft. Refer to Group 3,
Differential and Driveline, for proper procedure.
Fig. 5 Speedometer Components
1 – SENSOR O-RING
2 – SPEEDOMETER ADAPTER
3 – ADAPTER O-RING
4 – SPEEDOMETER PINION
5 – ADAPTER CLAMP
6 – VEHICLE SPEED SENSOR
ITEM
TORQUE
A
2-3 N·m (15-27 in. lbs.)
B
10-12 N·m (90-110 in. lbs.)
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NV231 TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
(3) Remove front output shaft yoke.
(4) Remove seal from front case with pry tool (Fig.
7).
INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 8143 as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 8). Once seal is started, continue tapping
seal into bore until installer tool seats against case.
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
REAR RETAINER AND OIL PUMP REMOVAL
(1) Remove the speedometer adapter.
(2) Spread band clamp which holds output shaft
boot to slinger with a suitable awl, or equivalent.
(3) Remove output shaft boot from slinger and out-
put shaft.
(4) Using
Puller
MD-998056-A,
remove
rear
slinger (Fig. 9).
(5) Use a suitable pry tool, or a slide hammer
mounted screw, to remove the seal from the rear
retainer (Fig. 10).
(6) Remove the rear output bearing I. D. retaining
ring (Fig. 11).
(7) Remove the bolts holding the rear retainer to
the rear case half.
(8) Tap rear retainer with rawhide or rubber mal-
let to loosen sealer bead.
Fig. 6 Location Of Index Numbers On Speedometer
Adapter
1 – SPEEDOMETER ADAPTER
2 – INDEX NUMBER LOCATION
Fig. 7 Remove Front Output Shaft Seal
1 – OUTPUT SHAFT SEAL
2 – PRYBAR
Fig. 8 Front Output Seal Installation
1 – INSTALLER 8143
2 – TRANSFER CASE
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NV231 TRANSFER CASE
21 - 351
REMOVAL AND INSTALLATION (Continued)
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