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Unread 01-25-2013, 02:20 PM   #1
RedHotChiliDog
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2004 TJ Wrangler 
 
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Transfer Case Replacement?

I finally got a new np-231 because my old one got ****ed up to say the least. Anyways Im putting it in tomorrow and my friends who might help probably wont come to the shop till Im an hour or two in Im assuming. So any tips or anything like that? How exactly do you do it? I have a Chiltons I was just looking in and it says to remove the tranny as well but from what Ive heard I shouldnt have to do that...

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Unread 01-25-2013, 02:23 PM   #2
biffgnar
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No need to remove the transmission. Support the transmssion with a jackstand, remove skid, disconnect everything that connects to the TC (driveshafts, speedo cable, breather, shift linkage, etc.), remove bolts that hold TC to transmssion, remove TC (actually may be easier if you drain it first also). Reverse with new TC.
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Unread 01-25-2013, 02:36 PM   #3
RedHotChiliDog
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Quote:
Originally Posted by biffgnar View Post
No need to remove the transmission. Support the transmssion with a jackstand, remove skid, disconnect everything that connects to the TC (driveshafts, speedo cable, breather, shift linkage, etc.), remove bolts that hold TC to transmssion, remove TC (actually may be easier if you drain it first also). Reverse with new TC.
Theres a huge hole on the side of my tcase so believe me its drained! And do I have to take my shift linkage off? I had to once before for a body lift (to replace one of the metal plate things) and it was a ***** to put it on and off. And one of the rubber gaskets got completely torn off last time
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Unread 01-25-2013, 02:42 PM   #4
biffgnar
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Quote:
Originally Posted by RedHotChiliDog View Post
Theres a huge hole on the side of my tcase so believe me its drained! And do I have to take my shift linkage off? I had to once before for a body lift (to replace one of the metal plate things) and it was a ***** to put it on and off. And one of the rubber gaskets got completely torn off last time
Just disconnect the linkage down at the TC itself so you don't mess with any of the rest of it.
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Unread 01-25-2013, 02:43 PM   #5
Ironturtle84
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http://www.advanceadapters.com/produ...ifter-bracket/

Get one of these. Cheap, easy to install, and takes the bs out of the linkage.

the driveshafts come off with 4 8mm bolts on each end on the front and axel end only for the rear
unclip speedo sensor and range sensor
drop skid
undo 6 14mm nuts that secure the tcase to the tranny
pull off
installation is reverse
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Unread 01-25-2013, 02:48 PM   #6
Wheelin98TJ
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Make sure the input gear length is the same between the new and old cases.
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Unread 01-25-2013, 05:54 PM   #7
RedHotChiliDog
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Quote:
Originally Posted by Wheelin98TJ View Post
Make sure the input gear length is the same between the new and old cases.
I did that believe me its from a 4.0L auto like my jeep
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Unread 01-25-2013, 07:33 PM   #8
DevilDogDoc
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The bolts that hold the TC to the trans are not metric, they are standard. I don't remember exactly what size it was but I believe it was 5/8. The metric worked on the easy to reach nuts but on the hard to get ones it started to strip the nuts out but the standard one worked perfect.
Edit:The FSM says its a .375-24 nut. So 3/8 not 5/8ths
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Unread 01-25-2013, 09:52 PM   #9
mrblaine
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Quote:
Originally Posted by DevilDogDoc View Post
The bolts that hold the TC to the trans are not metric, they are standard. I don't remember exactly what size it was but I believe it was 5/8. The metric worked on the easy to reach nuts but on the hard to get ones it started to strip the nuts out but the standard one worked perfect.
Edit:The FSM says its a .375-24 nut. So 3/8 not 5/8ths
A 9/16's ratchet wrench and lowering the transmission down as low as possible without BREAKING THE FAN SHROUD are good things to know and have.
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Unread 01-25-2013, 09:57 PM   #10
DevilDogDoc
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Hey now, my shroud was broken before I swapped out cases...
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