Jeep XJ. Manual — part 452
Description
Torque
Solenoid Harness Bolt . . . . 6–8 N·m (57–75 in. lbs.)
Speedometer Adapter Clamp Screw . . . . 10–12 N·m
(90–110 in. lbs.)
Speed Sensor Coupling Nut . . . . . . . . . . 14–20 N·m
(125–175 in. lbs.)
Throttle Cable Engine Bracket Screws . . 7–11 N·m
(63–94 in. lbs.)
Throttle Cable Retaining Screw
(at transmission) . . . . . 8–10 N·m (70–98 in. lbs.)
Transfer Case Mounting Nuts . . . . . . . . 30–41 N·m
(22–30 ft. lbs.)
Transmission Shift Lever Nut . . . . . . . . 15–17 N·m
(134–154 in. lbs.)
Transmission-To-Engine Block Bolts . . . 50–64 N·m
(37–47 ft. lbs.)
Valve Body Bolts (to case) . . . . . . . . . . . . 9–11 N·m
(80–96 in. lbs.)
Valve Body Bolts (to valve body) . . . . . . . . 6–7 N·m
(54–58 in. lbs.)
SPECIAL TOOLS
AW-4
C-484 Snap Ring Plier
C-3293-SP Gauge
C-3339 Dial Indicator Set
C-4959 Caliper, Metric Vernier
C-4960 Micrometer
7536 Puller, Oil Pump
7538 Compressor, Piston #2 Spring
7539 Compressor, Piston #3 Spring
21 - 344
AW–4 AUTOMATIC TRANSMISSION
XJ
SPECIFICATIONS (Continued)
7540 Pliers, Large Snap Ring
7542 Puller, Reaction Sleeve
7543 Puller, Piston #1
7544 Installer, Brake Drum Seal
7549 Installer, Seal
7552 Gauge, 3.0 mm Wire
7554 Adapter, Pressure Port
XJ
AW–4 AUTOMATIC TRANSMISSION
21 - 345
SPECIAL TOOLS (Continued)
NV231 TRANSFER CASE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 346
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 347
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 347
REMOVAL AND INSTALLATION
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 348
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 349
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . 350
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 350
DISASSEMBLY AND ASSEMBLY
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 351
CLEANING AND INSPECTION
NV231 TRANSFER CASE. . . . . . . . . . . . . . . . . . 369
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . 372
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
SPECIAL TOOLS
NV231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
DESCRIPTION AND OPERATION
NV231 TRANSFER CASE
DESCRIPTION
The NV231 is a part-time transfer case with a low
range reduction gear system. The NV231 has three
operating ranges plus a Neutral position. A low range
system provides a reduction ratio for increased low
speed torque capability.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
OPERATING RANGES
Transfer case operating ranges are:
• 2WD (2-wheel drive)
• 4x4 (4-wheel drive)
• 4 Lo (4-wheel drive low range
The 2WD range is for use on any road surface at
any time.
The 4x4 and 4 Lo ranges are for off road use only.
They are not for use on hard surface roads. The only
exception being when the road surface is wet or slip-
pery or covered by ice and snow.
The low range reduction gear system is operative
in 4 Lo range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 2.72:1.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever. The shift lever is connected to the trans-
fer case range lever by an adjustable linkage rod. A
straight line shift pattern is used. Range positions
are marked on the shifter bezel cover plate.
IDENTIFICATION
A circular ID tag is attached to the rear case of
each transfer case (Fig. 1). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.
The transfer case serial number also represents
the date of build.
OPERATION
The input gear is splined to the transmission out-
put shaft. The input gear drives the mainshaft
through the planetary assembly and range hub. The
front output shaft is operated by a drive chain that
connects the shaft to a drive sprocket on the main-
shaft. The drive sprocket is engaged/disengaged by
the mode fork, which operates the mode sleeve and
Fig. 1 Fill/Drain Plug And I. D. Tag Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
21 - 346
NV231 TRANSFER CASE
XJ
hub. The sleeve and hub are not equipped with a
synchronizer mechanism for shifting.
LUBRICANT AND FILL LEVEL
DESCRIPTION
Recommended lubricant for the NV231 transfer
case is Mopar
t Dexron II, or ATF Plus 3, type 7176.
Approximate lubricant fill capacity is 1.2 liters (2.5
pints).
The fill and drain plugs are both in the rear case
(Fig. 2). Correct fill level is to the bottom edge of the
fill plug hole. Be sure the vehicle is level to ensure
an accurate fluid level check.
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS
DIAGNOSIS CHART
Condition
Possible Cause
Correction
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant.
4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant.
1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Fig. 2 Fill/Drain Plug Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
XJ
NV231 TRANSFER CASE
21 - 347
DESCRIPTION AND OPERATION (Continued)
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