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Home >> Jeep >> 2004 >> Wrangler Sport, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Overhaul - NV241 Transfer Case) >> Transfer Case - NV241 >> Assembly >> Rear Extension

Rear Extension

WARNING: This page is about a different variant/trim than selected.
  1. Clean mating surfaces of transfer case housing and the rear retainer of any original gasket material.
  2. Apply bead of Mopar(R) Gasket Maker, or equivalent, to mating surface of rear case. Keep sealer bead width to maximum of 3/16 inch. Do not use excessive amount of sealer as excess will be displaced into case interior.
  3. Install the tone wheel dowel pin into the output shaft.
    Fig 1: Locating Output Shaft Dowel Pin
    G01708125Courtesy of DAIMLERCHRYSLER CORP.
  4. Install the speedometer sensor tone wheel onto the output shaft with the notch in the tone wheel inner diameter toward the front of the transfer case. Make sure the notch fits over the dowel pin in the output shaft and the tone wheel is against the rear output shaft bearing inner race.
    Fig 2: Installing Speedometer Sensor Tone Wheel
    G01708126Courtesy of DAIMLERCHRYSLER CORP.
  5. Align and install rear extension on rear case.
    Fig 3: Installing Rear Extension
    G01708127Courtesy of DAIMLERCHRYSLER CORP.
  6. Apply Mopar(R) Silicone Sealer to threads of rear extension bolts. Then install extension bolts. Tighten the extension bolts to 16-25 N.m (12-18 ft.lbs.).
    Fig 4: Installing Rear Extension Bolt
    G01708128Courtesy of DAIMLERCHRYSLER CORP.
  7. Install new seal in rear extension housing with Installer 9041 and Handle C-4171.
  8. Install the speedometer sensor into the extension housing.
    Fig 5: Installing Speedometer Sensor
    G01708129Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the speedometer sensor bolt. Tighten the bolt to 11-16 N.m (8-12 ft.lbs.).
    Fig 6: Installing Speedometer Sensor Bolt
    G01708130Courtesy of DAIMLERCHRYSLER CORP.
  10. Install the rear companion flange onto the output shaft.
  11. Install bolts into two threaded holes in the rear propeller shaft companion flange 180° apart.
    Fig 7: Removing & Installing Rear Companion Flange Nut
    G01708131Courtesy of DAIMLERCHRYSLER CORP.
  12. Place the Holder 6719 over the two bolts and use the Holder to install a new rear companion flange nut. See Fig 7 . Never re-use the companion flange nut once it has been installed. Tighten the companion flange nut to 122-176 N.m (90-130 ft.lbs.).
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