Jeep XJ. Manual — part 808
INPUT AND LOW RANGE GEAR
(1) Install first thrust washer in low range gear
(Fig. 48). Be sure washer tabs are properly aligned in
gear notches.
(2) Install input gear in low range gear. Be sure
input gear is fully seated.
(3) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(4) Install retainer on input gear and install snap-
ring.
INPUT GEAR AND LOW RANGE GEAR
(1) Align and install low range/input gear assem-
bly in front case (Fig. 49). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(2) Install snap-ring to hold input/low range gear
into front bearing (Fig. 50).
(3) Clean gasket sealer residue from retainer and
inspect retainer for cracks or other damage.
(4) Apply a 3 mm (1/8 in.) bead of Mopar
t gasket
maker or silicone adhesive to sealing surface of
retainer.
(5) Align cavity in seal retainer with fluid return
hole in front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying Mopar
T
gas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(6) Install bolts to hold retainer to transfer case
(Fig. 51). Tighten to 21 N·m (16 ft. lbs.) of torque.
MAINSHAFT
(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.
Fig. 47 Installing Rear Bearing In Retainer
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
3 - REAR RETAINER
Fig. 48 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 49 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
21s - 54
TRANSFER CASE NV-231
XJ
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
SHIFT FORKS AND MAINSHAFT
(1) Install new sector shaft O-ring and bushing
(Fig. 52).
(2) Install shift sector in case (Fig. 53). Lubricate
sector shaft with transmission fluid before installa-
tion.
(3) Install range lever, washer, and nut on sector
shaft (Fig. 54). Tighten range lever nut to 27-34 N·m
(20-25 ft. lbs.) torque.
(4) Assemble and install range fork and hub (Fig.
55). Be sure hub is properly seated in low range gear
and engaged to the input gear.
Fig. 50 Install Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 51 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 52 Sector O-Ring And Bushing Installation
1 - SECTOR BUSHING
2 - O-RING
Fig. 53 Shift Sector Installation
1 - SHIFT SECTOR
XJ
TRANSFER CASE NV-231
21s - 55
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
(5) Align and insert range fork pin in shift sector
slot.
(6) Install assembled mainshaft (Fig. 56). Be sure
shaft is seated in pilot bearing and input gear.
(7) Install new pads on mode fork if necessary.
(8) Insert mode sleeve in mode fork mode fork. Be
sure long side of sleeve is toward long end of shift
rail (Fig. 57).
(9) Install assembled mode fork and sleeve (Fig.
58). Be sure fork rail goes through range fork and
into case bore. Also be sure sleeve is aligned and
seated on mainshaft hub.
Fig. 54 Range Lever Installation
1 - RANGE LEVER
2 - LEVER NUT
Fig. 55 Install Range Fork And Hub Assembly
1 - RANGE HUB
2 - RANGE FORK
Fig. 56 Mainshaft Assembly Installation
1 - DRIVE SPROCKET
2 - MODE HUB
3 - MAINSHAFT
Fig. 57 Assembling Mode Fork And Sleeve
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 58 Mode Fork And Sleeve Installation
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
21s - 56
TRANSFER CASE NV-231
XJ
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
(10) Rotate sector to NEUTRAL position.
(11) Install new O-ring on detent plug (Fig. 59).
(12) Lubricate detent plunger with transmission
fluid or light coat of petroleum jelly.
(13) Install detent plunger, spring and plug (Fig.
59).
(14) Verify that plunger is properly engaged in sec-
tor.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Lubricate front output shaft-sprocket assembly,
drive chain, and drive sprocket with transmission
fluid.
(2) Assemble drive chain and front output shaft
(Fig. 60).
(3) Start chain on mainshaft drive sprocket.
(4) Guide front shaft into bearing and drive
sprocket onto mainshaft drive gear (Fig. 60).
(5) Install mode spring on upper end of mode fork
shift rail (Fig. 61).
OIL PUMP AND REAR CASE
(1) Install magnet in front case pocket (Fig. 62).
(2) Assemble oil pickup screen, connecting hose,
and tube.
Fig. 59 Shift Detent Components
1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)
Fig. 60 Installing Drive Chain And Front Output
Shaft
1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE SPROCKET
Fig. 61 Install Mode Fork Spring
1 - MODE SPRING
XJ
TRANSFER CASE NV-231
21s - 57
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
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