Jeep Wrangler TJ. Manual — part 522
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 39). 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. 40)
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.
Check the front case mounting studs and vent
tube. The tube can be secured with Loctite™ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoil™ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
Fig. 39 Seal Contact Surface Of Yoke Slinger
1 - FRONT SLINGER (PART OF YOKE)
2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 40 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
21 - 178
TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
ASSEMBLY
Lubricate transfer case components with Mopar
t
ATF +4, Automatic Transmission Fluid, or petroleum
jelly (where indicated) during assembly.
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
(1) Remove the front output shaft seal from case
with pry tool (Fig. 41).
(2) Remove the front output shaft bearing retain-
ing ring with screwdriver (Fig. 42).
(3) Remove bearing with Tool Handle C-4171 and
Tool 5065 (Fig. 43).
Fig. 41 Front Output Seal Removal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 42 Front Output Shaft Bearing Retaining Ring
Removal
1 - SCREWDRIVERS
2 - SNAP-RING
3 - FRONT OUTPUT SHAFT BEARING
4 - FRONT CASE
Fig. 43 Front Output Shaft Bearing Removal
1 - FRONT CASE
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 5065
TJ
TRANSFER CASE - NV231
21 - 179
TRANSFER CASE - NV231 (Continued)
(4) Install front output shaft front bearing in case
with Tool Handle C-4171 and Installer 5064 (Fig. 44).
(5) Install output shaft front bearing retaining
ring (Fig. 45). Start ring into place by hand. Then
use small screwdriver to work ring into case groove.
Be sure ring is fully seated before proceeding.
(6) Install new front output seal in front case with
Installer Tool 8143-A as follows:
(a) Place new seal on tool. Garter spring on
seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 46). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
(7) Remove the output shaft rear bearing with the
screw and jaws from Remover L-4454 and Cup 8148
(Fig. 47).
Fig. 46 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 47 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 44 Front Output Shaft Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
Fig. 45 Installing Output Shaft Front Bearing
Retaining Ring
1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL
SCREWDRIVER
21 - 180
TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 48). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 49).
(9) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing from inside the annulus
gear opening in the case (Fig. 50).
(10) Install locating ring on new bearing.
(11) Position case so forward end is facing upward.
(12) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing into case. The bearing
locating ring must be fully seated against case sur-
face (Fig. 51).
Fig. 48 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 49 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
Fig. 50 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 51 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
TJ
TRANSFER CASE - NV231
21 - 181
TRANSFER CASE - NV231 (Continued)
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