Jeep Wrangler TJ. Manual — part 520
(5) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 11).
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case.
The case alignment bolts require flat washers (Fig.
12).
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert pry tool blade only into
notches provided at each end of case (Fig. 13).
(4) Remove rear case from front case.
(5) Remove oil pickup tube from rear case (Fig.
14).
Fig. 14 Oil Pickup Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
Fig. 11 Range Lever Removal
1 - RANGE LEVER
2 - SECTOR SHAFT
Fig. 12 Rear Case Alignment Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLT (5)
3 - SPLINE HEAD BOLT (1)
Fig. 13 Loosening Rear Case - Typical
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
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TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
(6) Remove mode fork spring (Fig. 15).
(7) Pull front output shaft upward and out of front
output shaft bearing (Fig. 16).
(8) Remove front output shaft and chain.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 17).
(2) Remove mainshaft from mode sleeve and input
gear pilot bearing.
(3) Remove mode fork and sleeve as an assembly
(Fig. 18). Note position of sleeve for assembly refer-
ence. The short side of the sleeve faces upward.
Fig. 18 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 15 Mode Fork Spring Removal
1 - MODE SPRING
Fig. 16 Remove Front Output Shaft And Chain
1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING
Fig. 17 Detent Plug, Spring And Plunger Removal
1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)
TJ
TRANSFER CASE - NV231
21 - 171
TRANSFER CASE - NV231 (Continued)
(4) Remove range fork and hub as an assembly
(Fig. 19). Note fork position for installation reference.
(5) Remove shift sector from front case (Fig. 20).
(6) Remove shift sector bushing and O-ring (Fig.
21).
MAINSHAFT
(1) Remove mode hub retaining ring with heavy
duty snap-ring pliers (Fig. 22).
(2) Slide mode hub off mainshaft (Fig. 23).
Fig. 21 Sector Bushing And O-Ring Removal
1 - SEAL RETAINER
2 - SECTOR SHAFT BORE
3 - O-RING SEAL
Fig. 22 Mode Hub Retaining Ring Removal
1 - MODE HUB
2 - SNAP-RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING
Fig. 23 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 19 Range Fork And Sleeve Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 20 Shift Sector Removal
1 - SHIFT SECTOR
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TRANSFER CASE - NV231
TJ
TRANSFER CASE - NV231 (Continued)
(3) Slide drive sprocket off mainshaft (Fig. 24).
INPUT GEAR AND LOW RANGE GEAR
(1) Remove front bearing retainer attaching bolts
(Fig. 25).
(2) Remove front bearing retainer. Pry retainer
loose with pry tool positioned in slots at each end of
retainer (Fig. 26).
(3) Remove front bearing retainer seal. Tap seal
out with drift and hammer.
(4) Remove input gear retaining ring with heavy
duty snap-ring pliers (Fig. 27)
Fig. 24 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
Fig. 25 Front Bearing Retainer Bolts
1 - FRONT CASE
2 - FRONT BEARING RETAINER
3 - RETAINER BOLTS
Fig. 26 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
Fig. 27 Removing Input Gear Retaining Ring
1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
3 - SNAP-RING PLIERS
TJ
TRANSFER CASE - NV231
21 - 173
TRANSFER CASE - NV231 (Continued)
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