NV233 Transfer Case

ASSEMBLY




NV233 EXPLODED VIEW





Lubricate transfer case components with Mopar(R) ATF +4, Automatic Transmission Fluid or petroleum jelly (where indicated) during assembly.

BEARINGS AND SEALS

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.





1. Remove the front output shaft bearing retaining ring with pry tools.




2. Remove the front output shaft bearing with Universal Handle C-4171 (2) and Bearing Installer 5065 (3), inverted.




3. Install front output shaft front bearing with Universal Handle C-4171 (1) and Bearing Installer 5064 (2), inverted.




4. Install output shaft front bearing retaining ring (1). Start ring into place by hand. Then use small pry tool to work ring into case groove. Be sure ring is fully seated before proceeding.




5. Remove the output shaft rear bearing with Remover L-4454.




6. Install new bearing with Universal Handle C-4171 (1) and Bushing Installer 5066 (3).




7. The bearing bore is chamfered at the top. Install the bearing (1) so it is flush with the lower edge of this chamfer (2).




8. Using Seal Installer C-4210 (2) and Universal Handle C-4171 (1), drive input shaft bearing from inside the annulus gear opening in the case.




9. Install locating ring on new bearing.
10. Position case so forward end is facing upward.
11. Using Seal Installer C-4210 and Universal Handle C-4171, drive input shaft bearing into case. The bearing locating ring (1) must be fully seated against case surface.




12. Remove input gear pilot bearing by inserting a suitably sized drift (1) into the splined end of the input gear (2) and driving the bearing out with the drift and a hammer.




13. Install new pilot bearing with Bearing Installer 5065 (2) and Universal Handle C-4171 (1).




14. Remove seal from oil pump housing with a suitable pry tool
15. Install new seal (1) in oil pump housing (3) with Seal Installer 7888 (2).




16. Remove rear retainer bearing with Bearing Installer 5065 and Universal Handle C-4171.
17. Install rear bearing in retainer (3) with Universal Handle C-4171 (1) and Bearing Installer C-4210 (2).

INPUT AND LOW RANGE GEAR





1. Lubricate gears (3, 4) and thrust washers (5) with recommended transmission fluid.
2. Install first thrust washer (5) in low range gear (4). Be sure washer tabs are properly aligned in gear notches.
3. Install input gear (3) in low range gear (4). Be sure input gear is fully seated.
4. Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
5. Install retainer on input gear and install snap-ring.

INPUT GEAR AND LOW RANGE GEAR





1. Align and install low range/input gear assembly (2) in front case. Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.




2. Install snap-ring (2) to hold input/low range gear (1) into front bearing.




3. Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.
4. Apply a 3 mm (1/8 in.) bead of Mopar(R) Gasket Maker, or equivalent silicone adhesive, to sealing surface of retainer.
5. Align cavity in seal retainer with fluid return hole in front of case.

CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying Mopar(R) Gasket Maker, or equivalent silicone adhesive sealer. Seal failure and fluid leak can result.

6. Install bolts to hold retainer (1) to transfer case. Tighten to 16-25 Nm (12-18 ft. lbs.) of torque.




7. Remove front bearing retainer seal with suitable pry tool.
8. Install new front bearing retainer (1) with Seal Installer 10118 (2).

MAINSHAFT

1. Lubricate mainshaft splines with recommended transmission fluid.
2. Slide drive sprocket onto mainshaft.
3. Slide mode hub onto mainshaft.
4. Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove.

SHIFT FORKS AND MAINSHAFT





1. Install new sector shaft O-ring (2).




2. Install new sector shaft O-ring.
3. Install shift sector (1) in case. Lubricate sector shaft with transmission fluid before installation.




4. Assemble and install range fork (2) and hub (1). Be sure hub is properly seated in low range gear and engaged to the input gear.
5. Align and insert range fork pin in shift sector slot.




6. Install new pads on mode fork if necessary.
7. Insert mode sleeve (1) in mode fork. Be sure long side of sleeve is toward long end of shift rail (2).
8. Install assembled mode fork and sleeve (1). Be sure fork rail goes through range fork and into case bore




9. Rotate sector to NEUTRAL position.
10. Install new O-ring (2) on detent plug (3).
11. Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
12. Install detent plunger (1), spring (4), and plug (3).
13. Verify that plunger is properly engaged in sector.

FRONT OUTPUT SHAFT AND DRIVE CHAIN





1. Install the front output shaft, mainshaft and chain assembly as one.
2. Install front output shaft snap ring.




3. Install mode spring (1) on upper end of mode fork shift rail.

OIL PUMP AND REAR CASE





1. Install magnet in front case magnet pocket (1).




2. Assemble oil pickup screen, connecting hose, and tube.
3. Install new pickup tube O-ring (2) in oil pump (1).




4. Insert oil pickup tube (2) in oil pump 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(R) Gasket Maker, or equivalent 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 Nm (20-25 ft. lbs.) torque.

FRONT OUTPUT SHAFT SEAL





1. Install the new front output shaft seal (1) into position in the transfer case bore (2).




2. Install the new front output shaft seal with Installer 10117 (1).




3. Install the new front output shaft seal slinger (1) into position on the output shaft (2).
4. Install the front output shaft seal slinger with Installer 10117.




5. Install the seal boot (2) onto the seal slinger (3)
6. Install a new seal boot clamp onto the seal boot, at the seal slinger, and tighten the clamp with Crimp Tool C-4975-A.

REAR RETAINER





1. Install the gasket onto the rear case or apply 3 mm (1/8 in.) wide bead of Mopar(R) Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of rear retainer. Allow sealer to set-up slightly before proceeding.
2. Install rear retainer on rear case. Tighten retainer bolts to 27-34 Nm (20-25 ft. lbs.).
3. Install new output shaft bearing snap-ring (2). Lift mainshaft slightly to seat snap-ring in shaft groove, if necessary.
4. Apply 3 mm (1/8 in.) wide bead of Mopar(R) Gasket Maker, or equivalent silicone adhesive sealer, to mounting surface of extension housing. Allow sealer to set-up slightly before proceeding.
5. Install extension housing on rear retainer.
6. Install extension housing bolts and tighten to 27-34 Nm (20-25 ft. lbs.).

SHIFT MOTOR





CAUTION: If the original shift motor and mode sensor assembly bolts are reused, be sure to use Mopar(R) Lock & Seal or Loctite(TM) 242 to replenish the lock patch material originally found on the bolts.

1. Verify that the shift motor o-ring is clean and properly positioned inside the machined o-ring groove of the shift motor.
2. Add high temperature grease between the actuator and the transfer case mating surface for sealing purposes.

NOTE: Verify that the shift motor position and sector shaft orientation are aligned. It may be necessary to manually shift the transfer case if the shift motor and sector shaft are not aligned.

3. Position the shift motor and mode sensor assembly (2) onto the transfer case (1).
4. Install the bolts (3) to hold the shift motor and mode assembly (2) onto the transfer case (1). Tighten the bolts to 16-24 Nm (12-18 ft.lbs.).