Jeep XJ. Manual — part 458
(4) Apply liberal quantity of petroleum jelly to new
rear seal and to output shaft. Petroleum jelly is
needed to protect seal lips during installation.
(5) Slide seal onto Seal Protector 6992 (Fig. 77).
Slide seal protector and seal onto output shaft.
(6) Slide Installer C-4076-B onto seal protector
with the recessed side of the tool toward the seal.
Drive seal into rear bearing retainer with Installer
C-4076-B and Handle MD-998323 (Fig. 78).
(7) Install rear slinger with Installer 8408.
(8) Install boot on output shaft slinger and crimp
retaining clamp with tool C-4975-A (Fig. 79).
Fig. 74 Range Lever Installation
1 – RANGE LEVER
2 – WASHER
3 – LOCKNUT
Fig. 75 Output Shaft Yoke Installation
1 – OUTPUT SHAFT YOKE
2 – YOKE NUT
Fig. 76 Yoke Seal Washer Installation
1 – YOKE SEAL WASHER
Fig. 77 Output Shaft Seal and Protector
1 – OUTPUT SHAFT SEAL
2 – SPECIAL TOOL 6992
3 – TRANSFER CASE
Fig. 78 Rear Seal Installation
1 – SPECIAL TOOL C-4076–B
2 – SPECIAL TOOL MD998323
3 – TRANSFER CASE
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NV231 TRANSFER CASE
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
NV231 TRANSFER CASE
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and 3M
all purpose cleaner. Use compressed air to remove
solvent residue from oil feed passages in the case
halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket (Fig. 80). Minor nicks and
scratches can be smoothed with an oilstone. However,
replace any part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320–400 grit emery cloth but do
not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 81). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300–400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
Fig. 80 Mainshaft, Mode Hub, And Drive Sprocket
1 – MODE HUB
2 – DRIVE SPROCKET
3 – MAINSHAFT
4 – MODE HUB RETAINING RING
Fig. 79 Slinger Boot Installation
1 – SPECIAL TOOL C-4975–A
2 – SLINGER
3 – BOOT
4 – CLAMP
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NV231 TRANSFER CASE
21 - 369
CLEANING AND INSPECTION (Continued)
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 82). Minor nicks on the shift rail can
be smoothed with 320–400 grit emery cloth.
Inspect the shift fork wear pads (Fig. 83). The
mode fork pads are serviceable and can be replaced if
necessary. The range fork pads are not serviceable.
The fork must be replaced as an assembly if the pads
are worn or damaged.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
Inspect the retainer components (Fig. 84). Replace
the bearing if rough or noisy. Check the retainer for
Fig. 83 Shift Fork And Wear Pad Locations
1 – RANGE FORK
2 – MODE FORK
3 – WEAR PADS (SERVICEABLE)
4 – WEAR PADS (NON-SERVICEABLE)
Fig. 81 Input Gear And Carrier Components
1 – PLANETARY CARRIER
2 – REAR THRUST WASHER
3 – FRONT THRUST WASHER
4 – CARRIER LOCK RING
5 – CARRIER LOCK RETAINING RING
6 – INPUT GEAR
Fig. 82 Shift forks
1 – RANGE FORK
2 – MODE FORK AND RAIL
3 – MODE SPRING
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NV231 TRANSFER CASE
XJ
CLEANING AND INSPECTION (Continued)
cracks or wear in the bearing bore. Clean the
retainer sealing surfaces with a scraper and 3M all
purpose cleaner. This will ensure proper adhesion of
the sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Replace any part if distorted, bent, or broken. Also
replace the boot if cut or torn. Replace the boot band
clamps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 85). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke nut
and seal washer as neither part should be reused.
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320–400 grit emery
to smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 86)
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. Clean the sealing surfaces with a scraper and
3M all purpose cleaner. This will ensure proper
sealer adhesion at assembly. Replace the input
retainer seal; do not reuse it.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Fig. 84 Rear Retainer Components
1 – REAR RETAINER
2 – REAR BEARING I. D. RETAINING RING
3 – REAR SEAL
4 – BOOT
5 – BAND CLAMPS
6 – REAR SLINGER
7 – REAR BEARING O. D. RETAINING RING
8 – REAR BEARING
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NV231 TRANSFER CASE
21 - 371
CLEANING AND INSPECTION (Continued)
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