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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 >> Disassembly >> Rear Extension, Retainer, And Rear Case

Rear Extension, Retainer, And Rear Case

WARNING: This page is about a different variant/trim than selected.
  1. Install bolts into two threaded holes in the rear propeller shaft companion flange 180° apart.
    Fig 1: Removing Rear Companion Flange Nut
    G01708043Courtesy of DAIMLERCHRYSLER CORP.
  2. Place the Holder 6719 over the two bolts and use the Holder to remove the rear companion flange nut. See Fig 1 .
    3. NOTE: The companion flange is a taper fit onto the output shaft. It may be necessary to use Puller 8992 to remove the companion flange.
  3. Remove the rear companion flange from the output shaft.
  4. There is a seal slinger located on the rear of the companion flange that can be replaced if necessary. Use a suitable cold chisel to strike the slinger hub parallel to the centerline in several spots to expand the slinger hub. A new slinger can be driven onto the flange hub using a suitable pipe tool.
  5. Remove the speedometer sensor bolt.
    Fig 2: Removing Speedometer Sensor Bolt
    G01708044Courtesy of DAIMLERCHRYSLER CORP.
  6. Remove the speedometer sensor from he extension housing.
    Fig 3: Removing Speedometer Sensor
    G01708045Courtesy of DAIMLERCHRYSLER CORP.
  7. Remove rear extension bolts.
    Fig 4: Removing Rear Extension Bolt
    G01708046Courtesy of DAIMLERCHRYSLER CORP.
  8. Remove rear extension housing. Tap extension once or twice with a plastic mallet to break sealer bead and loosen it.
    Fig 5: Removing Rear Extension
    G01708047Courtesy of DAIMLERCHRYSLER CORP.
  9. Remove the speedometer sensor tone wheel from the output shaft.
    Fig 6: Removing Speedometer Sensor Tone Wheel
    G01708048Courtesy of DAIMLERCHRYSLER CORP.
  10. Remove the tone wheel dowel pin from the output shaft.
    Fig 7: Locating Output Shaft Dowel Pin
    G01708049Courtesy of DAIMLERCHRYSLER CORP.
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