Page 2481 of 2889

(11) Install rear output bearing and snap-ring to
output shaft.
COMPANION FLANGE
(1) Install companion flange seal on front shaft
(Fig. 90).
(2) Install companion flange on front shaft (Fig.
91). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.
REAR RETAINER AND EXTENSION
(1) Clean mating surfaces of transfer case housing
and the rear retainer of any original gasket material.
(2) Install new rear retainer gasket onto the trans-
fer case housing or rear retainer.
(3) Align and install rear retainer on rear case
(Fig. 92).
(4) Apply MopartSilicone Sealer to threads of rear
retainer bolts. Then install retainer bolts finger tight.
(5) Install output bearing on mainshaft and seat it
in rear retainer with suitable size pipe tool (Fig. 93).
Fig. 90 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 91 Installing Companion Flange On Front Shaft
1 - COMPANION FLANGE
Fig. 92 Rear Retainer Installation
1 - REAR RETAINER
2 - SHIFT RAIL
Fig. 93 Output Bearing Installation
1 - OUTPUT BEARING
2 - PIPE TOOL
21 - 846 TRANSFER CASE - NV231HDBR/BE
TRANSFER CASE - NV231HD (Continued)
Page 2482 of 2889

(6) Install output bearing retaining ring (Fig. 94).
(7) Tighten rear retainer bolts to 27-34 N´m (20-25
ft. lbs.) torque.
(8) Install new seal in rear extension housing seal
with suitable size installer tool.
(9) Apply bead of MopartGasket Maker, or equiv-
alent, to mating surface of rear extension housing.
Keep sealer bead width to maximum of 3/16 inch. Do
not use excessive amount of sealer as excess could be
displaced into output bearing.
(10) Align and install rear extension on retainer
(Fig. 95).(11) Apply MopartSilicone Sealer to threads of
rear extension housing bolts. Then install and
tighten bolts to 27-34 N´m (20-25 ft. lbs.) torque.
INSTALLATION
(1) Align and seat transfer case on transmission.
Be sure transfer case input gear splines are aligned
with transmission output shaft. Align splines by
rotating transfer case rear output shaft yoke if nec-
essary. Do not install any transfer case attaching
nuts until the transfer case is completely seated
against the transmission.
(2) Install and tighten transfer case attaching
nuts. Tighten nuts to 30-41 N´m (20-30 ft.lbs.).
(3) Install rear crossmember.
(4) Remove jack stand from under transmission.
(5) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Connect vacuum harness and vent hose.
(7) Connect shift rod to transfer case lever or floor
shift arm. Use channel lock style pliers to press rod
back into lever grommet.
(8) Adjust shift linkage, if necessary.
(9) Fill transfer case with recommended transmis-
sion fluid and install fill plug.
(10) Install skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - INSTALLATION)
(11) Lower vehicle
Fig. 94 Output Bearing Retaining Ring Installation
1 - OUTPUT BEARING
2 - RETAINING RING
Fig. 95 Rear Extension Housing Installation
1 - REAR EXTENSION
2 - RETAINER
3 - EXTENSION SEAL
BR/BETRANSFER CASE - NV231HD 21 - 847
TRANSFER CASE - NV231HD (Continued)
Page 2483 of 2889
SPECIFICATIONS
TRANSFER CASE
TORQUE SPECIFICATIONS
DESCRIPTION N-m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 12-18 -
Bolt, Diff. Case 17-27 15-24 -
Plug, Drain/Fill 40-45 30-40 -
Bolt, Extension Housing 35-46 26-34 -
Bolt, Front Brg. Retainer 16-27 12-24 -
Bolt, Case Half 35-46 26-34 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 20-25 -
Bolt, Rear Retainer 35-46 26-34 -
Nuts, Mounting 30-41 20-30 -
Bolts, U-Joint 19 17 -
Vacuum Switch 20-34 15-25 -
21 - 848 TRANSFER CASE - NV231HDBR/BE
TRANSFER CASE - NV231HD (Continued)
Page 2484 of 2889
SPECIAL TOOLS
TRANSFER CASE - NV231HD
Handle, Universal - C-4171
Installer, Seal - 8143-A
Installer, Bearing - 6953
Installer, Seal - C-4210
Remover, Bushing - 6957
Installer, Bushing - 8157
Installer, Seal - D-163
Installer, Seal - 7884
Installer, Bushing - 5066
BR/BETRANSFER CASE - NV231HD 21 - 849
TRANSFER CASE - NV231HD (Continued)
Page 2485 of 2889

EXTENSION HOUSING
BUSHING AND SEAL
REMOVAL
(1) Raise and support vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the extension housing seal.
(4) Using Remover 8158, remove bushing from
extension housing.
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in extension
housing with fluid port in bushing aligned with slot
in housing.
(3) Using Installer 8157, drive bushing into hous-
ing until installer seats against case.
(4) Using Installer D-163, install seal in extension
housing (Fig. 96).
(5) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
(6) Verify proper transfer case fluid level.
(7) Lower vehicle.
Plug, Extension - C-293-3
Tool Set - L-4518
Cup - 8148
Installer, Pump Housing Seal - 7888
Fig. 96 Install Rear Seal in Extension Housing
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL D-163
21 - 850 TRANSFER CASE - NV231HDBR/BE
EXTENSION HOUSING BUSHING AND SEAL (Continued)
Page 2486 of 2889

FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
REFILL
The fill and drain plugs are both in the rear case
(Fig. 97).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartATF +4, type 9602, Automatic
Transmission fluid.
(7) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.).
(8) Lower vehicle.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(4) Remove companion flange nut (Fig. 98).
(5) Remove companion flange from output shaft.
Use a suitable puller if flange can not be removed by
hand.(6) Remove companion flange rubber seal from
front output shaft (Fig. 99).
(7) Remove seal from front case with pry tool (Fig.
100).
Fig. 98 Removing Companion Flange Nut
1 - COMPANION FLANGE
2 - SOCKET
Fig. 99 Companion Flange Seal Removal
1 - FLANGE SEAL
Fig. 100 Remove Front Output Shaft Seal
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 97 Fill/Drain Plug and I.D. Tag Location - Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
BR/BETRANSFER CASE - NV231HD 21 - 851
Page 2487 of 2889

INSTALLATION
(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 ham-
mer (Fig. 101). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange seal on front shaft
(Fig. 102).
(3) Install companion flange on front shaft (Fig.
103). Then install and tighten flange nut to 176-271
N´m (130-200 ft. lbs.) torque.(4) Install propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION)
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 2H.
(2) Remove transfer case shifter knob cap.
(3) Remove nut holding shifter knob to shift lever.
(4) Remove shifter knob.
(5) Remove the shift boot from the shifter bezel.
(6) Remove the bolts securing the shifter mecha-
nism to the floor pan along the driver's side of the
transmission tunnel (Fig. 104).
(7) Raise and support the vehicle.
(8) Loosen adjusting trunnion lock bolt and slide
shift rod out of trunnion. If rod lacks enough travel
to come out of trunnion, push trunnion out of shift
lever.
(9) Remove the nuts holding the shifter mecha-
nism to the underside of the floor pan.
(10) Separate shift lever mechanism from the vehi-
cle.
Fig. 101 Front Output Seal Installation
1 - INSTALLER 8143-A
2 - TRANSFER CASE
Fig. 102 Installing Flange Seal On Front Shaft
1 - FRONT OUTPUT SHAFT
2 - FLANGE SEAL
Fig. 103 Installing Companion Flange On Front
Shaft
1 - COMPANION FLANGE
21 - 852 TRANSFER CASE - NV231HDBR/BE
FRONT OUTPUT SHAFT SEAL (Continued)
Page 2488 of 2889

INSTALLATION
(1) If the shifter mechanism does not have a
adjustment locating pin installed, align the adjust-
ment channel on the shifter assembly to the locating
hole in the lower shift lever and install an appropri-
ately sized pin to retain the position (Fig. 105).
(2) Position shift lever on vehicle.
(3) Install nuts to hold shift lever to the underside
of the body.
(4) Install trunnion to shift lever, if necessary.
(5) Install shift rod to trunnion, if necessary.
(6) Tighten the shift rod lock bolt to 10 N´m (90
in.lbs.).
(7) Remove the shifter adjustment locating pin
from the adjustment channel and the locating hole.
(8) Lower vehicle.
(9) Install the bolts to hold the shifter mechanism
to the floor pan.
(10) Install the transfer case shifter bezel.
(11) Install the shifter boot and the shifter knob
onto the shifter lever.
(12) Install nut to hold shifter knob to shift lever.
(13) Install shifter knob cap.
(14) Verify transfer case operation.
ADJUSTMENT - SHIFT LEVER
(1) Move shift lever into 2H position.
(2) Raise vehicle.(3) Loosen shift rod lock bolt at trunnion (Fig.
106).
Fig. 104 Transfer Case Shifter
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
Fig. 105 Shifter Adjustment
1 - LOCATING PIN
2 - ADJUSTMENT CHANNEL
3 - LOWER SHIFTER LEVER
4 - LOCATING HOLE
Fig. 106 Shift Rod Lock Bolt Location
1 - TRANSFER CASE SHIFTER ASSEMBLY
2 - SHIFT ROD
3 - TRUNNION
4 - LOCK BOLT
BR/BETRANSFER CASE - NV231HD 21 - 853
SHIFT LEVER (Continued)