TRANSMISSION AND TRANSFER CASE

CONTENTS
page page
AX15 MANUAL TRANSMISSION . . . . . . . . . . . . 1 NV231 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 7
AX15 MANUAL TRANSMISSION
GENERAL INFORMATION
AX 15 MANUAL TRANSMISSION
The AX 15 i s a 5speed, synchromesh, manual
transmi ssi on. Fi fth gear i s an overdri ve range wi th a
rati o of 0.79:1. The shi ft mechani sm i s i ntegral and
mounted i n the shi ft tower porti on of the adapter
housi ng (Fi g. 1).
TRANSMISSION IDENTIFICATION
The AX 15 i denti fi cati on code numbers are on the
bottom surface of the transmi ssi on gear case (Fi g. 2).
The fi rst number i s year of manufacture. The sec-
ond and thi rd numbers i ndi cate month of manufac-
ture. The next seri es of numbers i s the transmi ssi on
seri al number.
Fig. 1 AX 15 Manual Transmission
Fig. 2 Identification Code Number Location
ZG TRANSMISSION AND TRANSFER CASE 21 - 1
TRANSMISSION SHIFT PATTERN
The AX 15 shi ft pattern i s shown i n (Fi g. 3). Fi rst
and second and thi rd and fourth gear ranges are i n
l i ne for i mproved shi fti ng. Fi fth and reverse gear
ranges are al so i n l i ne at the extreme ri ght of the
pattern (Fi g. 3).
The AX 15 i s equi pped wi th a reverse l ockout
mechani sm. The shi ft l ever must be moved through
the Neutral detent before maki ng a shi ft to reverse.
TRANSMISSION LUBRICANT
Recommended l ubri cant for AX 15 transmi ssi ons i s
Mopar 75W90, API Grade GL5 gear l ubri cant, or
equi val ent.
Correct l ubri cant l evel i s from the bottom edge, to
no more than 6 mm (1/4 i n.) bel ow the bottom edge of
the fi l l pl ug hol e.
Approxi mate dry fi l l l ubri cant capaci ty i s:
3.10 l i ters (3.27 qts.) i n 4wheel dri ve model s
TRANSMISSION SWITCH AND PLUG LOCATIONS
The fi l l pl ug i s at the dri ver si de of the gear case
(Fi g. 4).
The drai n pl ug and backup l i ght swi tch are on the
passenger si de of the gear case (Fi g. 5).
TRANSMISSION GEAR RATIOS
AX 15 gear rati os are:
Fi rst gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.83:1
Second gear . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33:1
Thi rd gear . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44:1
Fourth gear . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00:1
Fi fth gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.79:1
Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22:1
TRANSMISSION ASSEMBLY INFORMATION
Lubri cate the transmi ssi on components wi th gear
l ubri cant duri ng assembl y. Use petrol eum jel l y to
l ubri cate seal l i ps and/or hol d parts i n pl ace duri ng
i nstal l ati on.
DIAGNOSIS AND TESTING
LOW LUBRICANT LEVEL
A l ow transmi ssi on l ubri cant l evel i s general l y the
resul t of a l eak, i nadequate l ubri cant fi l l , or an i ncor-
rect l ubri cant l evel check.
Leaks can occur at the mati ng surfaces of the gear
case, i ntermedi ate pl ate and adapter or extensi on
housi ng, or from the front/rear seal s. A suspected
l eak coul d al so be the resul t of an overfi l l condi ti on.
Leaks at the rear of the extensi on or adapter hous-
i ng wi l l be from the housi ng oi l seal s. Leaks at com-
ponent mati ng surfaces wi l l usual l y be the resul t of
i nadequate seal er, gaps i n the seal er, i ncorrect bol t
ti ghteni ng, or use of a nonrecommended seal er.
A l eak at the front of the transmi ssi on wi l l be from
ei ther the front beari ng retai ner or retai ner seal .
Lubri cant may be seen dri ppi ng from the cl utch
Fig. 3 AX 15 Shift Pattern
Fig. 4 Fill Plug Location
Fig. 5 Drain Plug/Backup Light Switch Location
21 - 2 TRANSMISSION AND TRANSFER CASE ZG
GENERAL INFORMATION (Continued)
housi ng after extended operati on. I f the l eak i s
severe, i t may al so contami nate the cl utch di sc caus-
i ng sl i p, grab and chatter.
Transmi ssi ons fi l l ed from ai r or el ectri cal l y pow-
ered l ubri cant contai ners can be under fi l l ed. Thi s
general l y happens when the contai ner del i very mech-
ani sm i s i mproperl y cal i brated. Al ways check the
l ubri cant l evel after fi l l i ng to avoi d an under fi l l con-
di ti on.
A correct l ubri cant l evel check can onl y be made
when the vehi cl e i s l evel ; use a dri veon hoi st to
ensure thi s. Al so al l ow the l ubri cant to settl e for a
mi nute or so before checki ng. These recommenda-
ti ons wi l l ensure an accurate check and avoi d an
underorover fi l l condi ti on.
HARD SHIFTING
Hard shi fti ng i s usual l y caused by a l ow l ubri cant
l evel , i mproper or contami nated l ubri cants, compo-
nent damage, i ncorrect cl utch adjustment, or by a
damaged cl utch pressure pl ate or di sc.
Substanti al l ubri cant l eaks can resul t i n gear, shi ft
rai l , synchro and beari ng damage. I f a l eak goes
undetected for an extended peri od, the fi rst i ndi ca-
ti ons of a probl em are usual l y hard shi fti ng and
noi se.
I ncorrect or contami nated l ubri cants can al so con-
tri bute to hard shi fti ng. The consequence of usi ng
nonrecommended l ubri cants i s noi se, excessi ve
wear, i nternal bi nd and hard shi fti ng.
I mproper cl utch rel ease i s a frequent cause of hard
shi fti ng. I ncorrect adjustment or a worn, damaged
pressure pl ate or di sc can cause i ncorrect rel ease. I f
the cl utch probl em i s advanced, gear cl ash duri ng
shi fts can resul t.
Worn or damaged synchro ri ngs can cause gear
cl ash when shi fti ng i nto any forward gear. I n some
new or rebui l t transmi ssi ons, new synchro ri ngs may
tend to sti ck sl i ghtl y causi ng hard or noi sy shi fts. I n
most cases, thi s condi ti on wi l l decl i ne as the ri ngs
weari n.
TRANSMISSION NOISE
Most manual transmi ssi ons make some noi se dur-
i ng normal operati on. Rotati ng gears can generate a
mi l d whi ne that may onl y be audi bl e at extreme
speeds.
Severe, obvi ousl y audi bl e transmi ssi on noi se i s
general l y the resul t of a l ubri cant probl em. I nsuffi -
ci ent, i mproper, or contami nated l ubri cant can pro-
mote rapi d wear of gears, synchros, shi ft rai l s, forks
and beari ngs. The overheati ng caused by a l ubri cant
probl em, can al so l ead to gear breakage.
REMOVAL AND INSTALLATION
TRANSMISSION
REMOVAL
1. Di sconnect the battery negati ve cabl e.
2. Remove the shi fter boot and shi fter.
3. Rai se the vehi cl e on a hoi st.
4. Drai n the transmi ssi on fl ui d (Fi g. 6).
5. Support the engi ne and transmi ssi on wi th an
adjustabl e jack stand.
6. Remove exhaust pi pe and heat shi el d.
7. Mark the front and rear propel l er shafts for
i nstal l ati on al i gnment (Fi g. 7).
8. Remove the front propel l er shaft.
9. Remove the rear propel l er shaft.
10. Remove the transmi ssi on ski d pl ate.
Fig. 6 Drain Plug and Backup Light Switch Location
Fig. 7 Marking Propeller Shaft and Axle Yoke
ZG TRANSMISSION AND TRANSFER CASE 21 - 3
DIAGNOSIS AND TESTING (Continued)
11. Di sconnect the transfer case l i nkage and vehi -
cl e speed sensor el ectri cal connector and vent tube
hose (Fi g. 8).
12. Reposi ti on the adjustabl e jackstand under the
engi ne.
13. Pl ace a transmi ssi on jack under the transmi s-
si on and secure the transmi ssi on wi th safety chai ns.
14. Remove the rear transmi ssi on mount.
15. Remove the rear crossmember.
16. Remove the transfer case assembl y. Refer to
Transfer Case removal l ater i n thi s Group.
17. Lower the engi ne and transmi ssi on no more
than 7.6 cm.
18. Remove the two (2) upper and two (2) mi d
cl utch housi ng to engi ne bol ts.
19. Remove the engi ne speed sensor (crankshaft
posi ti on sensor) (Fi g. 9).
20. Remove the cl utch sl ave cyl i nder from the
cl utch housi ng.
21. Remove the l ower transmi ssi on bol ts.
22. Remove the transmi ssi on assembl y from the
vehi cl e.
INSTALLATION
1. Mount the transmi ssi on on a transmi ssi on jack
and secure the transmi ssi on wi th safety chai ns.
2. I nstal l the transmi ssi on to the vehi cl e (Fi g. 10).
3. I nstal l the two (2) l ower transmi ssi on bol ts.
Ti ghten the bol ts to 74.6 Nm.
4. I nstal l the cl utch sl ave cyl i nder to the cl utch
housi ng.
5. I nstal l the engi ne speed sensor (crankshaft posi -
ti on sensor) to the vehi cl e (Fi g. 9).
6. I nstal l the two (2) upper cl utch housi ng to
engi ne bol ts. Ti ghten the bol ts to 36.6 Nm.
7. I nstal l the two (2) mi d cl utch housi ng to engi ne
bol ts. Ti ghten the bol ts to 58.3 Nm.
8. Rai se the engi ne and transmi ssi on wi th the
adjustabl e jackstand.
9. I nstal l the transfer case assembl y. Refer to
Transfer Case i nstal l ati on l ater i n thi s Group.
10. I nstal l the rear crossmember.
11. I nstal l the rear transmi ssi on mount.
12. Connect the transfer case l i nkage and vehi cl e
speed sensor el ectri cal connector and vent tube (Fi g.
8).
13. I nstal l the transmi ssi on ski d pl ate.
14. Al i gn and i nstal l the front and rear propel l er
shafts.
15. I nstal l the exhaust pi pe and heat shi el d.
Fig. 8 Vehicle Speed Sensor
Fig. 9 Engine Speed Sensor
21 - 4 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
16. Remove the transmi ssi on jack.
17. Fi l l the transmi ssi on wi th the proper fl ui d
(Fi g. 12).
18. Remove the adjustabl e jackstand from under
the engi ne.
19. Lower the vehi cl e from the hoi st.
20. I nstal l the shi fter boot and shi fter.
21. Reconnect the battery negati ve cabl e.
Fig. 10 Transmission to Engine Mounting
Fig. 11 Clutch Housing to Transmission
Fig. 12 Fill Plug Location
ZG TRANSMISSION AND TRANSFER CASE 21 - 5
REMOVAL AND INSTALLATION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Cl utch Housi ng to Engi ne
Top (2) Bol ts . . . . . . . . . . . . 36.6 Nm (27 ft. l bs.)
Cl utch Housi ng to Engi ne
Mi d-Poi nt (2) Bol ts . . . . . . . 58.3 Nm (43 ft. l bs.)
Cl utch Housi ng to Engi ne
Bottom (2) Bol ts . . . . . . . . . . 74.6 Nm (55 ft. l bs.)
Cl utch Housi ng to Transmi ssi on
bol ts . . . . . . . . . . . . . . . . . . . 38.0 Nm (28 ft. l bs.)
Transfer Case to Transmi ssi on
Attachi ng Nuts . . . . . . . . . . . . 35 Nm (26 ft. l bs.)
Propel l er Shaft Bol ts . . . . . . . 26.5 Nm (19.5 ft. l bs.)
21 - 6 TRANSMISSION AND TRANSFER CASE ZG
NV231 TRANSFER CASE
GENERAL INFORMATION
NV231 TRANSFER CASE
The NV231 i s a part-ti me transfer case wi th a l ow
range reducti on gear system. The NV231 has three
operati ng ranges pl us a Neutral posi ti on. A l ow range
system provi des a reducti on rati o for i ncreased l ow
speed torque capabi l i ty.
The i nput gear i s spl i ned to the transmi ssi on out-
put shaft. The i nput gear dri ves the mai nshaft
through the pl anetary assembl y and range hub. The
front output shaft i s operated by a dri ve chai n that
connects the shaft to a dri ve sprocket on the mai n-
shaft. The dri ve sprocket i s engaged/di sengaged by
the mode fork, whi ch operates the mode sl eeve and
hub. The sl eeve and hub are not equi pped wi th a
synchroni zer mechani sm for shi fti ng.
The geartrai n i s mounted i n two al umi num case
hal ves attached wi th bol ts. The mai nshaft front and
rear beari ngs are mounted i n al umi num retai ner
housi ngs bol ted to the case hal ves.
OPERATING RANGES
Transfer case operati ng ranges are:
2WD (2-wheel dri ve)
4x4 (4-wheel dri ve)
4 Lo (4-wheel dri ve l ow range
The 2WD range i s for use on any road surface at
any ti me.
The 4x4 and 4 Lo ranges are for off road use onl y.
They are not for use on hard surface roads. The onl y
excepti on bei ng when the road surface i s wet or sl i p-
pery or covered by i ce and snow.
The l ow range reducti on gear system i s operati ve
i n 4 Lo range onl y. Thi s range i s for extra pul l i ng
power i n off road si tuati ons. Low range reducti on
rati o i s 2.72:1.
SHIFT MECHANISM
Operati ng ranges are sel ected wi th a fl oor mounted
shi ft l ever. The shi ft l ever i s connected to the trans-
fer case range l ever by an adjustabl e l i nkage rod. A
strai ght l i ne shi ft pattern i s used. Range posi ti ons
are marked on the shi fter bezel cover pl ate.
TRANSFER CASE IDENTIFICATION
A ci rcul ar I D tag i s attached to the rear case of
each transfer case (Fi g. 1). The I D tag provi des the
transfer case model number, assembl y number, seri al
number, and l ow range rati o.
The transfer case seri al number al so represents
the date of bui l d.
RECOMMENDED LUBRICANT AND FILL LEVEL
Recommended l ubri cant for the NV231 transfer
case i s Mopar Dexron I I , or ATF Pl us 3, type 7176.
Approxi mate l ubri cant fi l l capaci ty i s 1.2 l i ters (2.5
pi nts).
The fi l l and drai n pl ugs are both i n the rear case
(Fi g. 1). Correct fi l l l evel i s to the bottom edge of the
fi l l pl ug hol e. Be sure the vehi cl e i s l evel to ensure
an accurate fl ui d l evel check.
Fig. 1 Fill/Drain Plug And I.D. Tag Locations
ZG TRANSMISSION AND TRANSFER CASE 21 - 7
DIAGNOSIS AND TESTING
NV231 DIAGNOSIS
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or will
not shift into desired range.
1) Vehicle speed to great to permit
shifting.
1) Slow vehicle and shift into
desired range.
2) If vehicle was operated for an
extended period in 4H mode on dry
surface, driveline torque load may
cause difficulty.
2) Stop vehicle and shift transfer
case to Neutral position. Transfer
case can then be shifted to the
desired mode.
3) Transfer case shift linkage
binding.
3) Repair or replace linkage as
necessary.
4) Insufficient or incorrect lubricant. 4) Drain and refill transfer case with
the correct type and quantity of
lubricant.
5) Internal transfer case
components binding, worn, or
damaged.
5) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Transfer case noisy while in, or
jumps out of, 4L mode.
1) Transfer case not completely
engaged in 4L position.
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Transfer case shift linkage out of
adjustment.
2) Adjust linkage as necessary.
3) Transfer case shift linkage loose
or binding.
3) Repair, replace, or tighten linkage
components as necessary.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
4) Repair or replace components as
necessary.
5) Low range gear worn or
damaged.
5) Repair or replace components as
necessary.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Abnormal tire wear. 1) Extended operation in 4H mode
on dry surfaces,
1) Operate vehicle in 2H mode on
dry surfaces.
21 - 8 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shi ft transfer case i nto Neutral .
(2) Rai se vehi cl e.
(3) Drai n transfer case l ubri cant.
(4) Mark front and rear propel l er shaft yokes for
al i gnment reference.
(5) Support transmi ssi on wi th jack stand.
(6) Remove rear crossmember and ski d pl ate, i f
equi pped.
(7) Di sconnect front/rear propel l er shafts at trans-
fer case.
(8) Di sconnect vehi cl e speed sensor wi res.
(9) Di sconnect transfer case l i nkage rod from
range l ever.
(10) Di sconnect transfer case vent hose (Fi g. 2)
and i ndi cator swi tch harness, i f necessary.
(11) Support transfer case wi th transmi ssi on jack.
(12) Secure transfer case to jack wi th chai ns.
(13) Remove nuts attachi ng transfer case to trans-
mi ssi on.
(14) Pul l transfer case and jack rearward to di sen-
gage transfer case.
(15) Remove transfer case from under vehi cl e.
INSTALLATION
(1) Mount transfer case on a transmi ssi on jack.
(2) Secure transfer case to jack wi th chai ns.
(3) Posi ti on transfer case under vehi cl e.
(4) Al i gn transfer case and transmi ssi on shafts
and i nstal l transfer case on transmi ssi on.
(5) I nstal l and ti ghten transfer case attachi ng nuts
to 35 Nm (Fi g. 2).
(6) Connect vehi cl e speed sensor wi res, and vent
hose.
(7) Connect i ndi cator swi tch harness to transfer
case swi tch, i f necessary. Secure wi re harness to cl i ps
on transfer case.
(8) Al i gn and connect propel l er shafts. Ti ghten
shaft attachi ng bol ts to 26.5 Nm torque.
(9) Fi l l transfer case wi th correct fl ui d. Refer to
Recommended Lubri cant And Fi l l Level secti on for
proper fl ui d and capaci ty.
(10) I nstal l rear crossmember and ski d pl ate, i f
equi pped. Ti ghten crossmember bol ts.
(11) Remove transmi ssi on jack and support stand.
(12) Connect shi ft rod to transfer case range l ever.
(13) Adjust transfer case shi ft l i nkage.
(14) Lower vehi cl e and veri fy transfer case shi ft
operati on.
SHIFT LEVER
REMOVAL
(1) Shi ft transfer case i nto 4L.
(2) Remove transfer case shi fter knob cap.
(3) Remove nut hol di ng shi fter knob to shi ft l ever.
(4) Remove shi fter knob.
(5) Rai se and support vehi cl e.
(6) Loosen adjusti ng trunni on l ock bol t and sl i de
shi ft rod out of trunni on (Fi g. 3). I f rod l acks enough
travel to come out of trunni on, push trunni on out of
shi ft l ever.
(7) Remove bol ts hol di ng shi ft l ever to transmi s-
si on.
(8) Separate shi ft l ever from vehi cl e.
INSTALLATION
(1) Posi ti on shi ft l ever on transmi ssi on. Use care
when passi ng the shi ft l ever through the shi fter boot
to prevent damage to the shi fter boot.
(2) I nstal l bol ts to hol d shi ft l ever to transmi ssi on.
(3) I nstal l trunni on to shi ft l ever, i f necessary.
(4) I nstal l shi ft rod to trunni on, i f necessary.
(5) Move shi ft l ever and transfer case to 4L posi -
ti on.
Fig. 2 Transfer Case Mounting
ZG TRANSMISSION AND TRANSFER CASE 21 - 9
(6) Ti ghten trunni on l ock bol t.
(7) Lower vehi cl e.
(8) I nstal l shi ft knob on shi ft l ever.
(9) I nstal l nut to hol d shi fter knob to shi ft l ever.
(10) I nstal l shi fter knob cap.
(11) Veri fy transfer case operati on.
SPEEDOMETER
REMOVAL
(1) Rai se vehi cl e.
(2) Di sconnect wi res from vehi cl e speed sensor.
(3) Remove adapter cl amp and screw (Fi g. 4).
(4) Remove speed sensor and speedometer adapter
as an assembl y.
(5) Remove speed sensor retai ni ng screw and
remove sensor from adapter.
(6) Remove speedometer pi ni on from adapter.
Repl ace pi ni on i f chi pped, cracked, or worn.
(7) I nspect sensor and adapter O-ri ngs (Fi g. 4).
Remove and di scard O-ri ngs i f worn or damaged.
(8) I nspect termi nal pi ns i n speed sensor. Cl ean
pi ns wi th Mopar el ectri cal spray cl eaner i f di rty or
oxi di zed. Repl ace sensor i f faul ty, or i f pi ns are l oose,
severel y corroded, or damaged.
INSTALLATION AND INDEXING
(1) Thoroughl y cl ean adapter fl ange and adapter
mounti ng surface i n housi ng. Surfaces must be cl ean
for proper adapter al i gnment and speedometer oper-
ati on.
(2) I nstal l new O-ri ngs on speed sensor and speed-
ometer adapter (Fi g. 4), i f necessary.
(3) Lubri cate sensor and adapter O-ri ngs wi th
transmi ssi on fl ui d.
(4) I nstal l vehi cl e speed sensor i n speedometer
adapter. Ti ghten sensor attachi ng screw to 2-3 Nm
(15-27 i n. l bs.) torque.
(5) I nstal l speedometer pi ni on i n adapter.
(6) Count number of teeth on speedometer pi ni on.
Do thi s before i nstal l i ng assembl y i n housi ng. Then
l ubri cate pi ni on teeth wi th transmi ssi on fl ui d.
(7) Note i ndex numbers on adapter body (Fi g. 5).
These numbers wi l l correspond to number of teeth on
pi ni on.
(8) I nstal l speedometer assembl y i n housi ng.
(9) Rotate adapter unti l requi red range numbers
are at 6 o-cl ock posi ti on. Be sure range i ndex num-
bers correspond to number of teeth on pi ni on gear.
(10) I nstal l speedometer adapter cl amp and retai n-
i ng screw. Ti ghten cl amp screw to 10-12 Nm (90-110
i n. l bs.) torque.
(11) Connect wi res to vehi cl e speed sensor.
(12) Lower vehi cl e and top off transmi ssi on fl ui d
l evel i f necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove front propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Remove front output shaft yoke.
(4) Remove seal from front case wi th pry tool (Fi g.
6).
Fig. 3 Shift Lever
21 - 10 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) I nstal l new front output seal i n front case wi th
I nstal l er Tool 8143 as fol l ows:
(a) Pl ace new seal on tool . Garter spri ng on seal
goes toward i nteri or of case.
(b) Start seal i n bore wi th l i ght taps from ham-
mer (Fi g. 7). Once seal i s started, conti nue tappi ng
seal i nto bore unti l i nstal l er tool seats agai nst case.
REAR RETAINER BUSHING AND SEAL
REMOVAL
(1) Rai se vehi cl e.
(2) Remove rear propel l er shaft. Refer to Group 3,
Di fferenti al and Dri vel i ne, for proper procedure.
(3) Usi ng a sui tabl e pry tool or sl i de-hammer
mounted screw, remove the rear retai ner seal .
(4) Usi ng Remover 6957, remove bushi ng from
rear retai ner (Fi g. 8).
Fig. 5 Location Of Index Numbers On Speedometer
Adapter Fig. 6 Remove Front Output Shaft Seal
Fig. 4 Speedometer Components
ZG TRANSMISSION AND TRANSFER CASE 21 - 11
REMOVAL AND INSTALLATION (Continued)
INSTALLATION
(1) Cl ean fl ui d resi due from seal i ng surface and
i nspect for defects.
(2) Posi ti on repl acement bushi ng i n rear retai ner
wi th fl ui d port i n bushi ng al i gned wi th sl ot i n
retai ner.
(3) Usi ng I nstal l er 8160, dri ve bushi ng i nto
retai ner unti l i nstal l er seats agai nst case (Fi g. 9).
(4) Usi ng I nstal l er C-3995-A, i nstal l seal i n rear
retai ner (Fi g. 10).
(5) I nstal l propel l er shaft.
(6) Veri fy proper fl ui d l evel .
(7) Lower vehi cl e.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE
Pl ug, Drai n/Fi l l . . . . . . . . . . . . . . . . . . . . . . 40 Nm
Nuts, Mounti ng . . . . . . . . . . . . . . . . . . . . . . 35 Nm
Swi tch, I ndi cator . . . . . . . . . . . . . . . . . . . . . 26 Nm
Fig. 7 Front Output Seal Installation
Fig. 8 Rear Retainer Bushing Removal
Fig. 9 Rear Retainer Bushing Install
Fig. 10 Install Rear Retainer Seal
21 - 12 TRANSMISSION AND TRANSFER CASE ZG
REMOVAL AND INSTALLATION (Continued)
SPECIAL TOOLS
SPECIAL TOOLSNV231
Installer, Seal8143
Remover, Bushing6957
Installer, Bushing8160
Installer, SealC-3995-A
ZG TRANSMISSION AND TRANSFER CASE 21 - 13