Installation

INSTALLATION / NV231 Transfer Case
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.

transfer case attaching nuts 35 Nm (26 ft. lbs.)


6. Connect vent hose.
7. Connect transfer case position sensor connector to sensor.
8. Align and connect propeller shafts.
9. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
10. Install skid plate.
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.






INSTALLATION / Transfer Case Position Sensor
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.

Transfer Case Position Sensor 20 - 34 Nm (15 - 25 ft. lbs.)

3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.





INSTALLATION / Shift Lever
1. Route the shift cable through the opening in the floor pan.
2. Position the shift mechanism over the shifter retaining studs on the floor pan.
3. Install the nuts to hold the shifter mechanism to the floor pan.


Shifter Mechanism Nuts 11.86 Nm (105 in. lbs.).


4. Install any floor console components previously removed.
5. Verify that the floor shifter is in the 4L position.
6. Raise vehicle.
7. Route the shift cable through the opening in the shift cable support bracket.
8. Install the cable and a new spring clip into the slot in the support bracket.
9. Install any additional routing clips on the shift cable.
10. Verify that the transfer case is in the 4L position. The 4L position for the transfer case is with the manual lever to the full rearward position.
11. Attach the shift cable to the transfer case manual lever.
12. Lower vehicle and check for proper transfer case shifter operation.




INSTALLATION / Front Output Shaft Seal
1. 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. Once seal is started, continue tapping seal into bore until installer tool seats against case.

2. Install the front output shaft companion flange.
3. Install the front propeller shaft.





INSTALLATION / Rear Output Shaft Seal
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. Slide seal protector and seal onto output shaft.






3. Slide Installer 8691 onto seal and mainshaft. Drive seal into rear bearing retainer.

NOTE: Vehicles built with a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.


4. Install a new output shaft rear slinger with Installer 8408, if the vehicle is not equipped with an output shaft damper.
5. 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.

NOTE: Be sure that the damper is installed with the raised mounting flange for the propeller shaft boot towards the rear of the mainshaft.






b. Position the Driver Installer 8680 onto the damper, making sure the legs of the installer are positioned through the slots of the damper.
c. Thread the puller screw from 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, 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.






6. Install boot on output shaft slinger, or output shaft damper, and crimp retaining clamp with tool C-4975-A.
7. Slide the slip yoke on the transmission/transfer case output shaft. Align installation reference marks at the axle yoke and install the propeller shaft.
8. Tighten the U joint strap/clamp bolts at the axle yoke to 19 Nm (14 ft. lbs.).
9. Crimp clamp with Clamp Tool C-4975A to hold dust boot to propeller shaft yoke.
10. Remove support and lower the vehicle.