Jeep XJ. Manual — part 454
(9) Remove rear retainer from rear case half (Fig.
12).
(10) Remove snap-ring holding oil pump in posi-
tion on output shaft.
(11) Disengage oil pickup tube from oil pump and
remove oil pump assembly. Remove oil pump by tilt-
ing the edge of the oil pump from under the edge of
the rear case half and sliding the pump (Fig. 13).
(12) Remove pick-up tube o-ring from oil pump
(Fig. 14), if necessary. Do not disassemble the oil
pump, it is not serviceable.
Fig. 9 Rear Slinger Removal
1 – TRANSFER CASE
2 – SPECIAL TOOL MD998056–A
3 – SLINGER
Fig. 10 Rear Retainer Seal
1 – REAR RETAINER
2 – OUTPUT SHAFT SEAL
Fig. 11 Output Shaft Rear Bearing Retaining Ring
1 – REAR RETAINER
2 – OUTPUT SHAFT SEAL
Fig. 12 Rear Retainer Removal
1 – MAINSHAFT
2 – REAR RETAINER
Fig. 13 Oil Pump Removal
1 – OIL PUMP
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NV231 TRANSFER CASE
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
YOKE AND RANGE LEVER REMOVAL
(1) Remove transfer case indicator switch.
(2) Remove front yoke nut as follows:
(a) Move range lever to 4L position.
(b) Then remove nut with socket and impact
wrench (Fig. 15).
(3) Remove yoke. If yoke is difficult to remove by
hand, remove it with bearing splitter, or with stan-
dard two jaw puller (Fig. 16). Be sure puller tool is
positioned on yoke and not on slinger as slinger will
be damaged.
(4) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(5) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 17).
Fig. 14 Pick-up Tube O-ring Location
1 – OIL PUMP
2 – O-RING
Fig. 15 Yoke Nut Removal
1 – IMPACT WRENCH
2 – SOCKET
3 – YOKE
Fig. 16 Yoke Removal
1 – PULLER TOOL
2 – YOKE
Fig. 17 Range Lever Removal
1 – RANGE LEVER
2 – SECTOR SHAFT
XJ
NV231 TRANSFER CASE
21 - 353
DISASSEMBLY AND ASSEMBLY (Continued)
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case.
The case alignment bolts require flat washers (Fig.
18).
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert pry tool blade only into
notches provided at each end of case (Fig. 19).
(4) Remove rear case from front case.
(5) Remove oil pickup tube from rear case (Fig.
20).
(6) Remove mode fork spring (Fig. 21).
(7) Pull front output shaft upward and out of front
output shaft bearing (Fig. 22).
(8) Remove front output shaft and chain.
Fig. 18 Rear Case Alignment Bolt Locations
1 – DOWEL BOLT AND WASHER (2)
2 – CASE BOLT (5)
3 – SPLINE HEAD BOLT (1)
Fig. 19 Loosening Rear Case
1 – REAR CASE
2 – PRY TOOL (IN CASE SLOT)
3 – FRONT CASE
Fig. 20 Oil Pickup Tube Removal
1 – CONNECTING HOSE
2 – PICKUP SCREEN
3 – PICKUP TUBE
Fig. 21 Mode Fork Spring Removal
1 – MODE SPRING
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NV231 TRANSFER CASE
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
SHIFT FORKS AND MAINSHAFT REMOVAL
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 23).
(2) Remove mainshaft from mode sleeve and input
gear pilot bearing.
(3) Remove mode fork and sleeve as an assembly
(Fig. 24). Note position of sleeve for assembly refer-
ence. The short side of the sleeve faces upward.
(4) Remove range fork and hub as an assembly
(Fig. 25). Note fork position for installation reference.
(5) Remove shift sector from front case (Fig. 26).
(6) Remove shift sector bushing and O-ring (Fig.
27).
Fig. 22 Remove Front Output Shaft And Chain
1 – DRIVE CHAIN
2 – FRONT OUTPUT SHAFT
3 – SHAFT FRONT BEARING
Fig. 23 Detent Plug, Spring And Plunger Removal
1 – POPPET
2 – SPRING
3 – SCREW
4 – POPPET BORE (IN CASE)
Fig. 24 Mode Fork And Sleeve Removal
1 – MODE SLEEVE
2 – MODE FORK AND RAIL
Fig. 25 Range Fork And Hub Removal
1 – RANGE HUB
2 – RANGE FORK
XJ
NV231 TRANSFER CASE
21 - 355
DISASSEMBLY AND ASSEMBLY (Continued)
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