Jeep Wrangler TJ. Manual — part 528
The 4H and 4LO 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 covered by
ice and snow.
The low range reduction gear system is operative
in 4LO range only. This range is for extra pulling
power in off road situations. Low range reduction
ratio is 4.0:1.
SHIFT MECHANISM
The transfer case is operated by an adjustable floor
mounted shift linkage. The transfer case shift lever
is directly attached to the shift sector. The sector
operates the range and mode forks within the trans-
fer case.
A straight line shift pattern is used with a NEU-
TRAL detent. Lever range positions are imprinted in
the shift knob.
SHIFTING
The vehicle must have the transmission placed in
NEUTRAL, or the clutch depressed in the case of a
manual transmission, and be moving less than 2-3
MPH when shifting into the 4L operating range.
DIAGNOSIS AND TESTING - TRANSFER CASE
Before beginning repair on a suspected transfer
case malfunction, check all other driveline compo-
nents beforehand.
The actual cause of a problem may be related to
such items as: front hubs, axles, propeller shafts,
wheels and tires, transmission, or clutch instead. If
all other driveline components are in good condition
and operating properly, refer to the Diagnosis Chart
for further information.
DIAGNOSIS CHART
Condition
Possible Cause
Correction
Transfer Case difficult to shift or will
not shift into desired range.
1) Vehicle speed too great to permit
shifting.
1) Stop vehicle and shift into
desired range. Or, reduce speed to
below 3-4 km/h (2-3 mph) before
attempting the shift.
2) If vehicle was operated for an
extended period in 4H on a dry
paved surface, the driveline torque
load may be causing a bind.
2) Stop vehicle and shift the
transmission into neutral. Shift the
transfer case to 2H and operate
vehicle in 2H on dry paved
surfaces.
3) Transfer case external shift
linkage binding.
3) Lubricate, repair, or replace
linkage bushings, or tighten loose
components as necessary.
4) Insufficient or incorrect lubricant.
4) Drain and refill to edge of fill hole
with Mopar
T
ATF +4, type 9602,
Automatic Transmission fluid.
5) Internal components binding,
worn, or damaged.
5) Disassemble the transfer case
and replace worn or damaged
components as necessary.
Fig. 2 Transfer Case Identification Tag and Fill/Drain
Plugs
1 - IDENTIFICATION TAG
2 - FILL PLUG
3 - DRAIN PLUG
21 - 202
TRANSFER CASE - NV241
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TRANSFER CASE - NV241 (Continued)
Condition
Possible Cause
Correction
Transfer Case noisy in all operating
ranges.
1) Insufficient or incorrect lubricant.
1) Drain and refill to edge of fill hole
with Mopar
T
ATF +4, type 9602,
Automatic Transmission fluid.
Noisy in, or jumps out of, four wheel
drive low range.
1) Transfer case not completely
engaged in 4L position.
1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Shift linkage out of adjustment.
2) Adjust linkage.
3) Shift linkage loose or binding.
3) Tighten, lubricate, or repair
linkage as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Disassemble unit and repair as
necessary.
5) Low range gear worn or
damaged.
5) Disassemble unit and repair as
necessary.
Lubricant leaking from output shaft
seal or vent.
1) Transfer case overfilled.
1) Drain lubricant to the correct
level.
2) Vent closed or restricted.
2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.
3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear.
1) Extended operation on hard, dry
surfaces in the 4H position.
1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and vacuum harness at
transfer case switch.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Remove rear crossmember.
(9) Mark front and rear propeller shafts for assem-
bly reference.
(10) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Move transfer case assembly rearward until
free of transmission output shaft.
(14) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
TJ
TRANSFER CASE - NV241
21 - 203
TRANSFER CASE - NV241 (Continued)
REAR EXTENSION, RETAINER, AND REAR CASE
(1) Install bolts into two threaded holes in the rear
propeller shaft companion flange 180° apart (Fig. 3).
(2) Place the Holder 6719 (Fig. 3) over the two
bolts and use the Holder to remove the rear compan-
ion flange nut.
(3) Remove the rear companion flange from the
output shaft.
NOTE: The companion flange is a taper fit onto the
output shaft. It may be necessary to use Puller 8992
to remove the companion flange.
(4) There is a seal slinger located on the rear of
the companion flange that can be replaced if neces-
sary. Use a suitable cold chisel to strike the slinger
hub parallel to the centerline in several spots to
expand the slinger hub. A new slinger can be driven
onto the flange hub using a suitable pipe tool.
(5) Remove the speedometer sensor bolt (Fig. 4).
(6) Remove the speedometer sensor (Fig. 5) from
the extension housing.
(7) Remove rear extension bolts (Fig. 6).
Fig. 3 Rear Companion Flange Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6719
3 - COMPANION FLANGE
4 - BOLTS
Fig. 4 Speedometer Sensor Bolt Removal
1 - EXTENSION HOUSING
2 - BOLT
3 - SPEEDOMETER SENSOR
Fig. 5 Speedometer Sensor Removal
1 - EXTENSION HOUSING
2 - SPEEDOMETER SENSOR
Fig. 6 Rear Extension Bolt Removal
1 - EXTENSION HOUSING
2 - BOLTS
21 - 204
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
(8) Remove rear extension housing (Fig. 7). Tap
extension once or twice with a plastic mallet to break
sealer bead and loosen it.
(9) Remove the speedometer sensor tone wheel
(Fig. 8) from the output shaft.
(10) Remove the tone wheel dowel pin (Fig. 9) from
the output shaft.
YOKE AND SHIFT LEVER
(1) Shift transfer case into a 4WD mode.
(2) Use Holder 6958 to secure the yoke and remove
the yoke nut (Fig. 10). Discard nut after removal. It
is not reusable.
(3) Remove the yoke (Fig. 11) from the front out-
put shaft.
NOTE: The yoke is a taper fit onto the output shaft.
It may be necessary to use a puller such as C-452
to remove the yoke.
(4) There is a seal slinger located on the rear of
the yoke that can be replaced if necessary. Use a
suitable cold chisel to strike the slinger hub parallel
to the centerline in several spots to expand the
slinger hub. A new slinger can be driven onto the
yoke hub using a suitable pipe tool.
(5) Remove yoke rubber seal from front output
shaft.
Fig. 7 Rear Extension Removal
1 - TRANSFER CASE
2 - EXTENSION HOUSING
Fig. 8 Speedometer Sensor Tone Wheel Removal
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - SENSOR TONE WHEEL
Fig. 9 Output Shaft Dowel Pin
1 - TRANSFER CASE
2 - OUPUT SHAFT
3 - DOWEL PIN
Fig. 10 Front Yoke Nut Removal
1 - TRANSFER CASE
2 - HOLDER 6958
3 - FRONT YOKE
TJ
TRANSFER CASE - NV241
21 - 205
TRANSFER CASE - NV241 (Continued)
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