Jeep Wrangler TJ. Manual — part 525
(9) Install boot on output shaft slinger, or output
shaft damper, and crimp retaining clamp with tool
C-4975-A (Fig. 83).
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N·m (26 ft. lbs.) torque (Fig. 2).
(6) Connect vehicle speed sensor wires, and vent
hose.
(7) Connect indicator switch harness to transfer
case switch, if necessary. Secure wire harness to clips
on transfer case.
(8) Align and connect propeller shafts. Refer to
Differential and Driveline for proper procedures and
specifications.
(9) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(10) Install
rear
crossmember,
or
skid
plate.
Tighten crossmember bolts to 41 N·m (30 ft. lbs.)
torque.
(11) Remove transmission jack and support stand.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage.
(14) Lower vehicle and verify transfer case shift
operation.
SPECIFICATIONS
TRANSFER CASE - NV231
TORQUE
DESCRIPTION
N·m
Ft. Lbs.
In. Lbs.
Plug, Detent
16-24
12-18
-
Plug, Drain/Fill
20-34
15-25
-
Bolt, Front Brg. Retainer
21
16
-
Bolt, Case Half
27-34
20-25
-
Nut, Front Yoke
122-176
90-130
-
Nut, Range Lever
27-34
20-25
-
Bolt, Rear Retainer
35-46
26-34
-
Nuts, Mounting
35-47
26-35
-
Switch, Indicator
20-34
15-25
-
Fig. 83 Slinger Boot Installation - Typical
1 - SPECIAL TOOL C-4975–A
2 - SLINGER
3 - BOOT
4 - CLAMP
21 - 190
TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
SPECIAL TOOLS
NV231
Installer - C-4076-B
Puller, Slinger - MD-998056-A
Installer - MD-998323
Protector, Seal - 8824
Installer, Boot Clamp - C-4975-A
Installer, Seal - 8143-A
Handle, Universal - C-4171
Installer, Seal - C-4210
Installer, Bearing - 5052
Installer, Bearing - 5065
TJ
TRANSFER CASE - NV231
21 - 191
TRANSFER CASE - NV231 (Continued)
Installer, Bushing - 5066
Installer, Bearing - 8128
Remover - L-4454
Cup - 8148
Installer, Seal - 7884
Installer, Pump Housing Seal - 7888
Installer, Transfer Case Damper Driver - 8422
Installer, Output Shaft Slinger - 8408
21 - 192
TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL
The fill and drain plugs are both in the rear case
(Fig. 84). 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) Raise vehicle.
(2) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft yoke.
(4) Remove seal from front case with pry tool (Fig.
85).
INSTALLATION
(1) 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. 86). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
Fig. 84 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 85 Remove Front Output Shaft Seal - Typical
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 86 Front Output Seal Installation - Typical
1 - INSTALLER 8143-A
2 - TRANSFER CASE
TJ
TRANSFER CASE - NV231
21 - 193
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