231-J Low231 4to1 Heavy Duty Transfer Case Instructions
Contents
1. r 231 J Low231 4 1 Heavy Duty TERAFLEX Transfer Case www teraflex com Kit 2104200 fits 6cyl manual Wranglers Kit 2104400 fits 4 amp 6cyl automatic Wranglers 87 02 Kit 2104100 fits 4cyl manual Wranglers and Cherokees Kit 2104303 fits 6cyl automatic Wranglers 2003 and XJ Cherokee automatic 23 spline Important Notes Prior to beginning this or any installation read these instructions to familiarize yourself with the required steps and evaluate if you are experienced and capable to personally perform these modifications A factory service manual should be used in conjunction with these installation instructions This assembly is depicted with a TeraFlex 231 Heavy Duty Short Shaft Kit 4444401 personal disassembly and assembly may differ Refer to the parts list to ensure that all necessary components and hardware has been included If any parts are missing please contact your local TeraFlex dealer for assistance Some older automatics require a transmission seal extension Please check for this part in your kit prior to installation If it is not included in your kit you can order it from your local distributer or from TeraFlex directly at 801 288 2585 Avoid high engine speeds when using the Low231 in low range in 4th or 5th gear with manual transmissions or with high gear automatics This is common when driving in snow mud or sand Because the gears are turning 50 faster and with the higher ratio it is p2. case by removing the 8 case half bolts Note the location of the 10 mm 12 point bolt Gently pry the case apart using the machined notches on either side of the case 119 Revision A 999080 www teraflex com Remove the range fork and shift hub Check the nylon pads Remove the detent screw spring and poppet Note if a 3 4 on the range fork and the mode fork for wear replace if nec wrench fits the detent screw you will need to purchase the essary Crown Automotive 15866 larger OEM detent parts Detent Poppet 53008217 Spring 53008218 Plug 53008216 O ring 4338956 oa M K pe ENESE A A a wee 7 V gt Remove the shift sector from the case Keep the O ring and bushing from the outside of the case 999080 Revision A www teraflex com 6 Using a flat head screwdriver remove the front output oil seal and snap ring With a plastic mallet remove the output bear ing Reassembly Now that all the needed parts have been removed from the factory transfer case take the new Heavy Duty Low231 case housing and prepare for assembly Clean all parts that will be reused thoroughly and inspect for wear Clean all mating surfaces with a brake parts cleaner Grease all bearings seals and O rings to prevent a dry start Follow all given torque Specs Reinstall the bearing retainer Torque to 16 ft lbs and the provided studs into the new Low231 Case half using th
3. attern to 15 20 ft lbs 7 ca gt Revision gt Reinstall the the pump b Li PSS Install a snap ring 1 followed by the speedometer gear 2 install the final snap ring 3 to retain the gear s iim WSN Apply a small amount of silicone to seal the spline and yoke interface under the yoke nut Apply red thread locking com pound to the yoke nut and torque to 90 130 ft lbs 999080 www teraflex com 9 Install seal washer on front output shaft install yoke Apply Apply a thin film of oil to the sensor o ring to aid in sensor red thread locking compound to nut and torque to 90 130 installation To be sure that the gears are engaged rotate the yoke with your hand on the sensor you should be able to feel the sensor turn Q MS N Fill transfer case with 2 2 pints 1 0L of ATF 4 and reinstall into vehicle if transfer case was removed Install soeedometer retainer fork tighten sensor bolt 8 12 ft Ibs Sa Break in Procedure for the Tera Low231 Drain and replace oil after 1000 and before 3000 miles One characteristic of a compound planetary unit such as the Tera Low231 is the associated gear noise Following installation of the Low231 you will likely hear noise caused by the gear configuration This is to be expected of the new gear system and can be reduced by following some simple break in or adju
4. chanisms Because of the higher center of gravity and larger tires this vehicle handles and reacts differently than many passenger cars both on and off road You must drive it safely Extreme care should be taken to prevent vehicle rollover or loss of control which can result in serious injury or death Avoid sudden sharp turns or abrupt maneuvers Generally braking performance and capabilities are decreased when significantly larger heavier tires are used especially when used in combination with transfer case low range reduction kits Take this into consideration while driving Do not add alter or fabricate any factory or aftermarket parts to increase vehicle height over the intended height of the Tera Flex product purchased Mixing component brand is not recommended TeraFlex Inc will not be responsible for any altered product or any improper installation or use of our products We will be happy to answer any questions concerning the design function and correct use of our products It is ultimately the buyer s respon sibility to have all bolts nuts checked for tightness after the first 100 miles and then every 3000 miles Wheel alignment steering system suspension and drive line systems must be inspected by a qualified professional mechanic at least every 3000 miles TERAFLEX PRODUCT WARRANTY TeraFlex Inc warrants TeraFlex Suspension products to the original retail purchaser to be free of defects in material and workmanship for as long as the o
5. e double nut method Thread two nuts onto the stud and tight en them against each other with wrenches Use them like the head of a bolt Install new front output seal Revision 999080 www teraflex com 7 Reinstall the range lever Torque to 22 ft lbs indicator switch Torque 20 ft lbs and new vent Reinstall detent screw spring and poppet Torque 15 ft lbs 25 R stall the pin on the fork Reinstall the mode fork shift rail and ring together shift sector Note the orientation of the synchro ring S EE einstall the range fork be sure to in into the groove cut into the J I O D ST gs ane Sa sia S gt gt _ p lt S Be sure the mating surfaces are free of oily residue Clean the magnet and reinstall along with the mode fork spring Ai a i me Yo S _ gt eZ NS ee AAA BEB DS ZG a _A Sa Z SSS a E w Y il Ea O CN Ys Qo Yas 2 ATI Revision A 999080 www teraflex com 8 Apply a maximum of 3 16 bead of gasket maker to the mat ing surface of front case half and install the rear half of the case Verify the shift rail and case alignment dowels are aligned Apply blue thread locking compound to bolts and tighten in a crisscross pattern torqueing to 20 25 ft lbs Apply a maximum 3 16 bead of gasket maker to the new tail housing install and torque bolts in a crisscross p
6. e information please contact a TeraFlex customer service repre sentative COPYRIGHT Copyright 2014 All rights reserved TeraFlex Inc Reproduction of this catalog and or any of its contents without written permission is strictly prohibited TeraFlex is a registered trademark of TeraFlex Inc All trade names and logos including but not limited to TeraFlex FlexArms RockGuard Monster and LCG are protected by law and duplication of trade names and or logos are strictly prohibited TeraFlex Inc reserves the right to update discontinue redesign modify finish part number or component build parts if deemed necessary without written notice TeraFlex Inc and any associated dealers are not responsible for misprints or typographical errors that may have inadvertently been made within this instruction sheet Jeep and the Jeep grill are registered trademarks of Fiat Chrysler Automobiles N V and have no affiliation with TeraFlex Inc TERAFLEX inc 5680 West Dannon Way West Jordan Utah 84081 Phone 801 713 3314 Fax 801 713 2313 www teraflex com Revision A 999080
7. not included in the kit FREE replacement stickers and instructions are available by request It is the installers duty to ensure a safe and controllable vehicle after the modifications have been performed WARNING Neither the seller nor the manufacturer will be liable for any loss damage or injury directly or indirectly arising from the use of or inability to determine the use of these products Before using the user shall determine the suitability of the products for its intended use and the user shall assume all responsibility and risk in connection therewith WARNING TO DRIVER This vehicle has been modified to enhance off road performance and has unique handling characteristics Use in harsh environments can cause extreme stress on the components Vehicle should be inspected after being off road to make sure that all the components are in working order and safe to travel on the highway All fasteners should be checked so that they are at the correct torque specifications as the vibration and stresses from off roading may cause critical fasteners to work loose Extra care should be taken to inspect the critical components steering and brake systems During each oil change components such as arms tie rod ends etc should be greased and checked for excessive wear Any worn components should be replaced When returning to the pavement always set or restore tire air pressure to the factory recommendation and connect or engage any disabled sway bar me
8. ossible to input speeds to reach 6500 RPM and cause damage to the transfer case We recommend using a lower gear in high range for higher speeds rather than running the Low231 at extreme RPM s Tools needed e Snap ring pliers e Red thread locking compound e This installation guide e Mallet or dead blow hammer e Blue thread locking compound e Basic mechanics tool set e RTV Gasket Maker Revision A 999080 www teraflex com 2 Parts List Description Quantity Check to make sure all parts and hardware are present before starting installation If any parts are missing please contact you local TeraFlex dealer for assistance Revision A 999080 www teraflex com 3 Begin by draining the oil from the transfer case Some will require a 15 16 socket or wrench while others will require a 10 mm allen socket or wrench Installation of the Low231 4 1 Heavy Duty Transfer Case requires that the transfer case be removed from the vehicle After removal from the vehicle check and compare the spline count and shaft length of you old case with the new case to verify that you have the correct case for the application Remove the rear driveline completely and disconnect the front driveline at the transfer case yoke Tie the front driveline out of the way Complete removal is not necessary Revision A 999080 www teraflex com 4 Remove the rear output shaft seal Remove the rear output shaft snap ring 7 S Peh P r Split the
9. riginal purchaser owns the vehicle on which products were originally installed Failure to complete regular maintenance grease every 3000 miles on TeraFlex FlexArms will void this warranty All other conditions of the standard TeraFlex product warranty apply All TeraLow products are covered by the TeraFlex two 2 year warranty to be free of defects in material and workmanship for two years from date purchased TeraFlex axles are covered by a 12 month warranty to be free of defects in materials and workmanship This warranty does not cover or include product finish improperly installed or applied products improperly maintained products products or components used for racing or competition or damage due to abuse or neglect products that fail due to the use of larger tire and wheel combinations All returns must be accompanied by an original invoice It is the customer s responsibility to remove the product from the vehicle Shipping charges are the respon sibility of the customer TeraFlex Inc will pay the return freight if the product meets the terms of warranty This warranty is for the replacement or repair of defective TeraFlex products only and does not include freight charges labor charges for removal of or installation of TeraFlex or related products or components costs incurred due to down time of the vehicle or lost profits due to vehicle down time A returned goods authorization number RGA must accompany any returned products For mor
10. stment guidelines Run the vehicle in low range A good day on the trail should be sufficient for the gears to quiet down Running the vehicle in low range in a park ing lot while accelerating and decelerating will also help quiet the gears The planetary gears are idle in all positions except low range The more low range use the gears experience the quieter they be come in all positions NP 231 TORQUE SPECIFICATIONS DESCRIPTION Ft Lbs Plug Detent 16 24 12 18 Plug Drain Fill 20 34 15 25 Bolt Front Brg Retainer 21 Bolt Case Half Nut Front Yoke Nut Range Lever Bolt Rear Retainer 2 34 122 176 2 34 20 25 90 130 20 25 26 34 26 35 mn on Nuts Mounting Switch Indicator 15 28 Revision A 999080 www teraflex com 10 PRODUCT INFORMATION MAINTENANCE INFORMATION It is the buyer s responsibility to have all suspension drivetrain steering and other components checked for proper tightness and torque after the first 100 miles and every 3000 miles after that NOTICE TO INSTALLER The enclosed Warning to Driver sticker must be installed in the vehicle in driver s view This sticker is to act as a constant safety reminder when operating the vehicle It is your responsibility as the equipment installer to install the provided sticker and to forward the product instructions to the vehicle s owner for review If a Warning to Driver sticker or product installation guide were
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