Jeep Wrangler TJ. Manual — part 534
(7) Install new seal in rear extension housing with
Installer 9041 and Handle C-4171.
(8) Install the speedometer sensor (Fig. 89) into
the extension housing.
(9) Install the speedometer sensor bolt (Fig. 90).
Tighten the bolt to 11-16 N·m (8-12 ft.lbs.).
(10) Install the rear companion flange onto the
output shaft.
(11) Install bolts into two threaded holes in the
rear propeller shaft companion flange 180° apart
(Fig. 91).
(12) Place the Holder 6719 (Fig. 91) over the two
bolts and use the Holder to install a new rear com-
panion flange nut. Never re-use the companion
flange nut once it has been installed. Tighten the
companion flange nut to 122-176 N·m (90-130 ft.lbs.).
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N·m (20-30 ft.lbs.).
(3) Install rear crossmember.
(4) Remove jack stand from under transmission.
(5) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL
&
DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Connect vacuum harness and vent hose.
(7) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(8) Adjust shift linkage, if necessary.
(9) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(10) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(11) Lower vehicle
Fig. 89 Speedometer Sensor Installation
1 - EXTENSION HOUSING
2 - SPEEDOMETER SENSOR
Fig. 90 Speedometer Sensor Bolt Installation
1 - EXTENSION HOUSING
2 - BOLT
3 - SPEEDOMETER SENSOR
Fig. 91 Rear Companion Flange Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6719
3 - COMPANION FLANGE
4 - BOLTS
21 - 226
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
SPECIFICATIONS
TRANSFER CASE - NV241
TORQUE SPECIFICATIONS
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Plug, Detent
16-25
12-18
-
Plug, Drain/Fill
20-34
15-25
-
Bolt, Rear Extension
16-24
12-18
-
Bolt, Front Input Retainer
21
16
-
Bolt, Case Half
20-27
15-20
-
Nut, Front Yoke
122-176
90-130
-
Nut, Rear Companion Flange
258-312
190-230
-
Bolt, Shift Lever
20-34
15-25
-
Nuts, Mounting
30-41
20-30
-
Bolts, U-Joint
19
17
-
Support, Sector
27-42
20-30
-
Sensor, Transfer Case Position
20-34
16-25
-
Bolt, Speed Sensor
11-16
8-12
-
SPECIAL TOOLS
TRANSFER CASE - NV241
Puller - C-452
Handle, Universal - C-4171
Remover - L-4454
Installer, Bushing - 5066
Holder, Yoke - 6719A
TJ
TRANSFER CASE - NV241
21 - 227
TRANSFER CASE - NV241 (Continued)
Installer, Bearing - 6953
Spanner Wrench - 6958
Cup - 8148
Installer, Bearing - 8239
Remover - 8240
Installer, Seal - 8841
Flange Puller - 8992
Installer, Cup Seal - 9045
Installer, Bearing - 9047
21 - 228
TRANSFER CASE - NV241
TJ
REAR EXTENSION SEAL (Continued)
REAR EXTENSION SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove the rear companion flange from the
output shaft.
(4) Using a suitable pry tool or slide-hammer
mounted screw, remove the rear extension seal.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Using
Installer
9041
and
Handle
C-4171,
install seal in rear extension (Fig. 92).
(3) Install the companion flange onto the output
shaft.
(4) Install a new companion flange nut and tighten
to 176-271 N·m (130-200 ft.lbs.).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL
The fill and drain plugs are both in the rear case
(Fig. 93). 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.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(4) Using Spanner Wrench 6958, remove yoke nut
(Fig. 94). Discard nut after removal. It is not reus-
able.
Fig. 92 Install Rear Extension Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 9041
Fig. 93 Transfer Case Identification Tag and
Fill/Drain Plugs
1 - IDENTIFICATION TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 94 Front Yoke Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6958
3 - FRONT YOKE
TJ
TRANSFER CASE - NV241
21 - 229
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