Assembly
TRANSFER CASE - NV231ASSEMBLY
Lubricate transfer case components with Mopar ATF +4, type 9602, 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 seal from case with pry tool (Fig. 41).
2. Remove the front output shaft bearing retaining ring with screwdriver (Fig. 42).
3. Remove bearing with Tool Handle C-4171 and Tool 5065 (Fig. 43).
4. Install front output shaft front bearing in case with Tool Handle C-4171 and Installer 5064 (Fig. 44).
5. Install output shaft front bearing retaining ring (Fig. 45). Start ring into place by hand. Then use small screwdriver to work ring into case groove. Be sure ring is fully seated before proceeding.
6. 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 hammer (Fig. 46). Once seal is started, continue tapping seal into bore until installer tool bottoms against case.
7. Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 47).
8. Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 48). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 49).
9. Using Remover C-4210 and Handle C-4171, drive input shaft bearing from inside the annulus gear opening in the case (Fig. 50).
10. Install locating ring on new bearing.
11. Position case so forward end is facing upward.
12. Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated against case surface (Fig. 51).
13. Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig. 52).
14. Install new pilot bearing with Installer 5065 and Handle C-4171 (Fig. 53).
15. Remove front bearing retainer seal with suitable pry tool.
16. Install new front bearing retainer seal with Installer 7884 (Fig. 54).
17. Remove seal from oil pump housing with a suitable pry tool
18. Install new seal in oil pump housing with Installer 7888 (Fig. 55).
19. Remove rear retainer bearing with Installer 8128 and Handle C-4171.
20. Install rear bearing in retainer with Handle C-4171 and Installer 5064 (Fig. 56).
INPUT AND LOW RANGE GEAR
1. Install first thrust washer in low range gear (Fig. 57). Be sure washer tabs are properly aligned in gear notches.
2. Install input gear in low range gear. Be sure input gear is fully seated.
3. Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
4. Install retainer on input gear and install snap-ring.
INPUT GEAR AND LOW RANGE GEAR
1. Align and install low range/input gear assembly in front case (Fig. 58). 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 to hold input/low range gear into front bearing (Fig. 59).
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 gasket maker or 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 gasket maker or silicone adhesive sealer. Seal failure and fluid leak can result.
6. Install bolts to hold retainer to transfer case (Fig. 60). Tighten to 21 Nm (15 ft. lbs.) of torque.
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 and bushing (Fig. 61).
2. Install shift sector in case (Fig. 62). Lubricate sector shaft with transmission fluid before installation.
3. Install range lever, washer, and nut on sector shaft (Fig. 63). Tighten range lever nut to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
4. Assemble and install range fork and hub (Fig. 64). 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 assembled mainshaft (Fig. 65). Be sure shaft is seated in pilot bearing and input gear.
7. Install new pads on mode fork if necessary.
8. Insert mode sleeve in mode fork mode fork. Be sure long side of sleeve is toward long end of shift rail (Fig. 66).
9. Install assembled mode fork and sleeve (Fig. 67). Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub.
10. Rotate sector to NEUTRAL position.
11. Install new O-ring on detent plug (Fig. 68).
12. Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
13. Install detent plunger, spring and plug (Fig. 68).
14. Verify that plunger is properly engaged in sector.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Lubricate front output shaft-sprocket assembly, drive chain, and drive sprocket with transmission fluid.
2. Assemble drive chain and front output shaft (Fig. 69).
3. Start chain on mainshaft drive sprocket.
4. Guide front shaft into bearing and drive sprocket onto mainshaft drive gear (Fig. 69).
5. Install mode spring on upper end of mode fork shift rail (Fig. 70).
OIL PUMP AND REAR CASE
1. Install magnet in front case pocket (Fig. 71).
2. Assemble oil pickup screen, connecting hose, and tube.
3. Install new pickup tube O-ring in oil pump (Fig. 72).
4. Insert oil pickup tube 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 (Fig. 73).
6. Apply 3 mm (1/8 in.) wide bead of Mopar 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 (Fig. 74).
9. Tighten case bolts to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
YOKE AND RANGE LEVER
1. Install indicator switch in front case. Tighten switch to 20 - 34 Nm (15 - 25 ft. lbs.) torque.
2. Install range lever, washer and locknut on sector shaft (Fig. 75). Tighten locknut to 27 - 34 Nm (20 - 25 ft. lbs.) torque.
3. Install new seal washer on front output shaft (Fig. 77).
4. Lubricate yoke hub with transmission fluid and install yoke on front shaft.
5. Install new seal washer on front shaft.
6. Install yoke and new yoke nut on front output shaft (Fig. 76).
7. Tighten yoke nut to 122 - 176 Nm (90 - 130 ft. lbs.) torque. Use Tool C-3281, or similar tool to hold yoke while tightening yoke nut.
REAR RETAINER
1. Apply bead of Mopar 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 rear retainer on rear case. Tighten retainer bolts to 20 - 27 Nm (15 - 20 ft. lbs.) torque.
3. Install rear bearing I.D. retaining ring and spacer on output shaft.
4. Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
5. Slide seal onto Seal Protector 6992 (Fig. 78). Slide seal protector and seal onto output shaft.
6. Slide Installer C-4076-B onto seal protector with the recessed side of the tool toward the seal. Drive seal into rear bearing retainer with Installer C-4076-B and Handle MD-998323 (Fig. 79).
NOTE: Vehicles built with a 4.OL engine and a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.
7. Install a new output shaft rear slinger with Installer 8408, if the vehicle is not equipped with an output shaft damper.
8. If the vehicle is equipped with an output shaft damper, install the output shaft damper as follows:
a. Position the damper weight on the output shaft. Start the damper onto the output shaft chamfer, being careful to keep the weight square to the output shaft. (Fig. 80)
b. Position the driver portion of Installer 8422 (Fig. 81) onto the damper, making sure the legs of the damper are positioned through the slots of the damper.
c. Thread the puller screw of Installer 8422 into the output shaft by hand only. Make sure the screw is fully threaded into the output shaft.
d. Using a wrench to hold the pulling screw stationary (Fig. 82), turn the pulling screw nut until the driver legs contact the rear face of the transfer case rear retainer. When the legs contact the retainer, the damper is properly positioned on the output shaft.
9. Install boot on output shaft slinger, or output shaft damper, and crimp retaining clamp with tool C-4975-A (Fig. 83).