Jeep Wrangler TJ. Manual — part 527
ADJUSTMENTS - SHIFT LINKAGE
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
97).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
SPEEDOMETER DRIVE
ADAPTER
REMOVAL
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 98).
(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. 98).
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
(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. 98), 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. 99).
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.
Fig. 97 Shift Linkage
1 - TRANSFER CASE SHIFT LEVER SHAFT
2 - SEAL
3 - TRANSFER CASE SHIFT LEVER ASSEMBLY
4 - FLOORPAN
5 - TRUNNION LOCK BOLT
6 - SHIFT ROD
7 - ADJUSTING TRUNNION
8 - TORQUE SHAFT BRACKET
9 - RANGE LEVER
10 - TORQUE SHAFT ROD
11 - TORQUE SHAFT
12 - LINKAGE BRACKET
21 - 198
TRANSFER CASE - NV231
TJ
SHIFT LEVER (Continued)
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
VEHICLE SPEED SENSOR
DESCRIPTION
The 3-wire Vehicle Speed Sensor (VSS) is located
on the speedometer pinion gear adapter. If equipped
with 4WD, this adapter is located on the extension
housing
of
the
transfer
case
(drivers
side).
If
equipped with 2WD, this adapter is located on the
left side of the transmission extension housing.
OPERATION
The VSS is a 3-circuit (3–wire), magnetic, hall-ef-
fect sensor.
The 3 circuits are:
• A 5-volt power supply from the Powertrain Con-
trol Module (PCM).
• A ground is provided for the sensor though a
low-noise sensor return circuit in the PCM.
• An input to the PCM is used to determine vehi-
cle speed and distance traveled.
The speed sensor generates 8 pulses per sensor
revolution. These signals, in conjunction with a
closed throttle signal from the throttle position sen-
sor, indicate a closed throttle deceleration to the
PCM. When the vehicle is stopped at idle, a closed
throttle signal is received by the PCM (but a speed
sensor signal is not received).
Under deceleration conditions, the PCM adjusts
the Idle Air Control (IAC) motor to maintain a
desired MAP value. Under idle conditions, the PCM
adjusts the IAC motor to maintain a desired engine
speed.
Fig. 98 Speedometer
1 - Sensor O-ring
5 - Adapter Clamp
2 - Speedometer Adapter
6 - Vehicle Speed Sensor
3 - Adapter O-ring
A - 2-3 N·m (15-27 in. lbs.)
4 - Speedometer Pinion
B - 10-12 N·m (90-110 in. lbs.)
Fig. 99 Location Of Index Numbers On Speedometer
Adapter
1 - SPEEDOMETER ADAPTER
2 - INDEX NUMBER LOCATION
TJ
TRANSFER CASE - NV231
21 - 199
SPEEDOMETER DRIVE ADAPTER (Continued)
REMOVAL
The Vehicle Speed Sensor (VSS) is located on the
speedometer pinion gear adapter. If equipped with
4WD, this adapter is located on the transfer case
extension (left side) (Fig. 100). If equipped with 2WD,
this adapter is located on the extension housing of
the transmission (left side).
(1) Raise and support vehicle.
(2) Disconnect electrical connector from sensor by
pushing slide tab (Fig. 100). After slide tab has been
positioned, push in on secondary release lock (Fig.
100) on side of connector and pull connector from
sensor.
(3) Remove sensor mounting bolt (Fig. 101).
(4) Remove sensor (pull straight out) from speed-
ometer pinion gear adapter (Fig. 101). Do not remove
gear adapter from transmission.
INSTALLATION
(1) Clean
inside
of
speedometer
pinion
gear
adapter before installing speed sensor.
(2) Install sensor into speedometer gear adapter
and install mounting bolt. Before tightening bolt, ver-
ify speed sensor is fully seated (mounted flush) to
speedometer pinion gear adapter.
(3) Tighten sensor mounting bolt to 2.2 N·m (20 in.
lbs.) torque.
(4) Connect electrical connector to sensor.
Fig. 100 VSS Location
1 - SENSOR ELECTRICAL CONNECTOR
2 - SLIDE TAB
3 - 4WD TRANSFER CASE EXTENSION
4 - VEHICLE SPEED SENSOR
5 - RELEASE LOCK
Fig. 101 VSS Removal/Installation
1 - ELECTRICAL CONNECTOR
2 - SENSOR MOUNTING BOLT
3 - O-RING
4 - SPEEDOMETER PINION GEAR
5 - SPEEDOMETER PINION GEAR ADAPTER
6 - O-RING
7 - VEHICLE SPEED SENSOR
21 - 200
TRANSFER CASE - NV231
TJ
VEHICLE SPEED SENSOR (Continued)
TRANSFER CASE - NV241
TABLE OF CONTENTS
page
page
TRANSFER CASE - NV241
. . . . . . . . . . . . . . . . . . . . . . . . 201
. . . . . . . . . . . . . . . . . . . . . . . . . . 201
DIAGNOSIS AND TESTING - TRANSFER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
. . . . . . . . . . . . . . . . . . . . . . . . 203
. . . . . . . . . . . . . . . . . . . . . . . . . . . 214
. . . . . . . . . . . . . . . . . . . . . . . . . 214
. . . . . . . . . . . . . . . . . . . . . . . . . . . 215
. . . . . . . . . . . . . . . . . . . . . . . . 226
REAR EXTENSION SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
. . . . . . . . . . . . . . . . . . . . . . . . 229
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
FRONT OUTPUT SHAFT SEAL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
. . . . . . . . . . . . . . . . . . . . . . . . 230
POSITION SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
. . . . . . . . . . . . . . . . . . . . . . . . 231
SHIFT LEVER
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
. . . . . . . . . . . . . . . . . . . . . . . . 233
VEHICLE SPEED SENSOR
. . . . . . . . . . . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . . . . . . . . . . . . 233
. . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
. . . . . . . . . . . . . . . . . . . . . . . . 234
TRANSFER CASE - NV241
DESCRIPTION
The NV241 transfer case (Fig. 1) is a part-time
transfer case with a low-range gear system. It pro-
vides three operating ranges plus a NEUTRAL posi-
tion.
The
low
range
position
provides
a
gear
reduction ratio of 4.0:1 for increased low speed torque
capability.
The gear cases, retainer and extension are all of
aluminum. Drive sprockets and an interconnecting
drive chain are used to transmit engine torque to the
front/rear propeller shafts. The mainshaft, input gear
and front output shaft are supported by ball and nee-
dle bearings.
IDENTIFICATION
An identification tag (Fig. 2) is attached to the rear
case of every transfer case. The 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
OPERATING RANGES
Transfer case operating ranges are:
• 2H (2-wheel drive)
• 4H (4-wheel drive)
• 4LO (4-wheel drive low range
The 2H range is for use on any road surface at any
time.
Fig. 1 NV241 - Front View
TJ
TRANSFER CASE - NV241
21 - 201
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