Jeep Liberty KJ. Manual — part 1228
SENSOR-POSITION
DESCRIPTION
The transfer case position sensor (2) is an electronic
device whose output can be interpreted to indicate the
transfer case’s current operating mode. The sensor
consists of a five position, resistive multiplexed circuit
which returns a specific resistance value to the Pow-
ertrain Control Module (PCM) for each transfer case
operating mode. The sensor is located on the top of
the transfer case, just left of the transfer case center-
line and rides against the sector plate roostercomb.
The PCM supplies 5VDC (+/- 0.5V) to the sensor and
monitors the return voltage to determine the sector
plate, and therefore the transfer case, position.
OPERATION
During normal vehicle operation, the Powertrain Con-
trol Module (PCM) monitors the transfer case position
sensor return voltage to determine the operating mode
of the transfer case. Refer to the Operating Mode Ver-
sus Resistance table for the correct resistance for
each position. Note that the NEUTRAL position is
allowed to float between sensor positions 3 and 4. If a
resistance is measured anywhere in either range, the
sensor is operating correctly.
Operating Mode Versus Resistance
SENSOR POSITION
OPERATING MODE
SENSOR RESISTANCE (ohms)
1
2WD
1124-1243
2
4WD PART TIME
650-719
3
NEUTRAL
389-431
4
NEUTRAL
199-221
5
4WD LOW
57-64
Position Sensor Linear Movement
1 - POSITION 1 - 10mm ±0.5mm
2 - POSITION 2 - 12mm ±0.5mm
3 - POSITION 3 - 14mm ±0.5mm
4 - POSITION 4 - 16mm ±0.5mm
5 - POSITION 5 - 18mm ±0.5mm
6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION
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TRANSFER CASE - NV231
KJ
REMOVAL
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor con-
nector from the position sensor (2).
3. Remove the position sensor from the transfer case.
INSTALLATION
1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 N·m (20 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.
KJ
TRANSFER CASE - NV231
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SEAL-REAR OUTPUT SHAFT
REMOVAL
1. Shift the transmission and transfer case into NEU-
TRAL.
2. Raise and support vehicle.
3. Mark a line across the pinion shaft and at each end
of the propeller shaft for installation reference.
4. Remove the U-joint strap bolts at the pinion shaft
yoke.
5. Pry open clamp holding the dust boot (2) to propel-
ler shaft yoke.
6. Slide the slip yoke off of the transmission/transfer
case output shaft and remove the propeller shaft.
7. Spread band clamp which holds output shaft boot
to the output shaft slinger with a suitable awl, or
equivalent.
8. Remove output shaft boot from slinger and output
shaft.
9. Remove the output shaft rear slinger (3) using
Puller MD-998056-A (2).
10. Use a suitable pry tool, or a slide hammer
mounted screw, to remove the seal (2) from the
rear retainer (1).
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TRANSFER CASE - NV231
KJ
INSTALLATION
1. Apply liberal quantity of petroleum jelly to new rear
seal and to output shaft. Petroleum jelly is needed
to protect seal lips during installation.
2. Slide seal onto Seal Protector 8824 (2). Slide seal
protector and seal onto output shaft.
3. Slide Installer 8691 (1) onto seal and mainshaft.
Drive seal into rear bearing retainer.
4. Install a new output shaft rear slinger with Installer
9023.
5. Install boot (3) on output shaft slinger and crimp
retaining clamp with tool C-4975-A (1).
6. Slide the slip yoke on the transmission/transfer
case output shaft. Align installation reference marks
at the axle yoke and install the propeller shaft.
7. Tighten the U-joint strap/clamp bolts at the axle
yoke to 19 N·m (14 ft. lbs.).
8. Crimp clamp with Clamp Tool C-4975A to hold dust
boot to propeller shaft yoke.
9. Remove support and lower the vehicle.
KJ
TRANSFER CASE - NV231
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