Jeep Liberty KJ. Manual — part 1226
4. Insert oil pickup tube (2) in oil pump (1) inlet.
5. Position assembled oil pump and pickup tube in
rear case. Be sure pickup screen is securely
seated in case slot. Also be sure oil pump locating
tabs are outside rear case.
6. Apply 3 mm (1/8 in.) wide bead of Mopar
T
gasket
maker or silicone adhesive sealer to mounting
flange of front case. Work sealer bead around bolt
holes.
7. Lift rear case and oil pump and carefully position
assembly on front case. Be sure case dowels are
aligned and that mode fork rail extends through
rear case before seating rear case on front case.
8. Install case attaching bolts. Alignment bolts at each
end of case are only ones requiring washers (1).
9. Tighten case bolts to 27-34 N·m (20-25 ft. lbs.) torque.
COMPANION FLANGE AND RANGE LEVER
1. Install range lever (1) and bolt (2) on sector shaft.
Tighten bolt to 27-34 N·m (20-25 ft. lbs.) torque.
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TRANSFER CASE - NV231
KJ
2. Inspect the o-ring on the transfer case position
sensor. Replace the o-ring if necessary.
3. Install the transfer case position sensor (1) in the
front case. Tighten sensor to 20-34 N·m (15-25 ft.
lbs.) torque.
4. Install new seal washer (1) on front output shaft.
5. Lubricate companion flange hub with transmission
fluid and install flange onto the front output shaft.
6. Install new seal washer on front shaft.
7. Install new flange nut onto front output shaft.
8. Tighten flange nut to 122-176 N·m (90-130 ft. lbs.)
torque.
REAR RETAINER
1. Apply bead of Mopar
T
Sealer P/N 82300234, or
Loctite™ Ultra Gray, to mating surface of rear
retainer. Sealer bead should be a maximum of 3/16
inch.
2. Install the forward rear output shaft bearing locating
snap-ring.
3. Install rear retainer on rear case. Tighten retainer
bolts to 20-27 N·m (15-20 ft. lbs.) torque.
4. Install rear bearing I.D. retaining ring onto output
shaft.
5. Apply liberal quantity of petroleum jelly to new rear
seal and to output shaft. Petroleum jelly is needed
to protect seal lips during installation.
6. Slide seal onto Seal Protector 8824 (2). Slide seal
protector and seal onto output shaft.
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TRANSFER CASE - NV231
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7. Slide Installer 8691 (1) onto seal and mainshaft.
Drive seal into rear bearing retainer.
8. Install a new output shaft rear slinger with Installer
9023.
9. Install boot on output shaft slinger and crimp retain-
ing clamp with tool C-4975-A (1).
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.
6. Connect vent hose.
7. Connect transfer case position sensor connector to sensor.
8. Align and connect propeller shafts. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPEL-
LER SHAFT - INSTALLATION).
9. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
10. Install skid plate. (Refer to 13 - FRAME & BUMPERS/FRAME/TRANSFER CASE SKID PLATE - INSTALLA-
TION)
11. Remove transmission jack and support stand.
12. Connect shift cable to transfer case range lever.
13. Lower vehicle and verify transfer case shift operation.
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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 Companion
Flange
122-176
90-130
-
Bolt, Range Lever
27-34
20-25
-
Bolt, Rear Retainer
35-46
26-34
-
Nuts, Mounting
35-47
26-35
-
Sensor, Transfer Case
Position
20-34
15-25
-
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TRANSFER CASE - NV231
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