RubiCrawler for Jeep TJ with Stock Transfer Case
Contents
1. nector clip from the transfer case shifter bracket See Figure 11 Usingan 8mm socket remove the five transfer case shifter bracket bolts Make sure to save these bolts as they will be reused ad Figure 10 Indicator Light Using a 10 mm socket remove the four bolts securing the shifter pivot assembly See Figure 12 Youwill have to liftup the carpet to get to these bolts The bracket will fall when the bolts are removedifitisn theld Seal the bolt holes with the four supplied black plastic plugs 11 Remove the transfer case shifter and thelinkage by lifting itup and out through the floor See Figure 13 12 Route the new RubiCrawler cable as Figure 12 Shifter Pivot shownin the picture Assembly Bolts di See Figure 14 Figure 14 RubiCrawler Cable Routing SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally a2. but the stick out could vary which would cause a major problem If you experience a problem DO NOT proceed call Advance Adapters The next two steps are time sensitive and should be completed in under 10 minutes Reclean the transmission face and the front face of the RubiCrawler using solvent Apply an 1 8 bead of the supplied Chrysler RTV to the RubiCrawleras shown in Figure 24 Figure 24 RTV Pattern SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 9 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 4 Reinstall the O ring as shown in Figure 24 This is very important for the RubiCrawler and Transmi
3. 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 SHIFTING INSTRUCTIONS Transfer Case Shifting The transfer case can be shifted from two wheel drive to 4 wheel drive HIGH while the vehicle is moving To shift the transfer case into four wheel drive LOW you must shift the transmission to neutral and the vehicle speed must be below 2 mph The transfer case can be shifted at a complete stop but it is easier to shift the unit when at a very slow roll RubiCrawler Shifting The RubiCrawler must be shifted when the transmission is in neutral and the vehicle speed is less than 2 mph The RubiCrawler can be shifted ata complete stop but it is easier to shift the unit when ata very slow roll Do NOT try to force the shift levers as serious damage to the shifters or unit can occur Serious damage to the RubiCrawler can occur if the proper shifting instructions are not followed JK Shift knobs Shift Knobs and Shift Patterns The shift knobs and patterns can be seen below and on the next page JK T TE Case Shift Pattern SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the will void any possible warranty or retin priv roy dag Pomegranates gpl dey my complete i Tocounwnend ihat yon contact ou sales t for more information This instuction shest is only to be wed for the assembly of Advance Adapter components We recommend that a nay Ligier aite ee ene ree wi
4. 9 09 Paso Robles CA 93447 PAGE 4 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Disassembly Preparation For Assembly 1 Usean Advance Adapters Uni Raise PN 15 1000 See Figure 1 or some other device to support the transmission pan to supportits weight Take caution to avoid denting the pan and damaging the transmis sion Remove the four M10 foot mountnuts from the crossmember Removecrossmember and any aftermarket skid plates 4 Remove both drive shafts Disconnect the Ee UN Rais breather hose position switch connector and the vehicle speed sensor VSS connector from the transfer case See Figure 2 Disconnect the wiring harness from the tailhousing by prying up the retaining clip on the driver s side of tailhousing Also disconnect the shift linkage rod Removethefoot mountfrom the tailhousing of the transmission by unbolting the four hex head bolts and sliding off of the exhaust hanger Removethe transfer case from the ha P vehicle by removing the 6 nuts from the transfer case studs rm Using astubby 9 16 wrench n makes this part much easier Remove the spud shaft by follow ing one of the three suggested methods below The end of the i spud shaft is tapped M10 1 5 E i Slide Hammer factory service Bla il manual method Note aggressive Figure 3 Custom Puller Method use may be necessary i Custom Puller recommend
5. ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 1 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 09 25 15 RUBICRAWLER JEEP TJ W NP231 amp NP241 KIT CONSISTS OF Optional Items No Qty PartNo Description Part No Description RUBL TJ GEAR BOX 15 1000 UNI RAISE Drivetrain Lifing Device Kit also Includes 42R360 CHRYSLER ATF 4 Qty 4 Recommemded 42R350 CHRYSLERRTV SEALANT 42R370 42RLE Transmission Filter 42R540 BOLT M10 1 5 X 30mm BHCS 42R800 RUBICRAWLER CONTROL MODULE 720015 WASHER 10mm FLAT 300474 Rubber Front Output Yoke Washer 720028 BOLT M10 1 5 X 35mm SHCS 720073 BOLT M10 1 5 X 25mm HHCS 42R TJS TWINSTICKSHIFTERKIT This kit includes shift knobs for both the NP231 Kit Includes and NP241transfer case One knob and one shift 302069 STUD 3 8 16 3 8 24 lever will not be used 303303 RETAINER SHIFTER BODY BARREL 303305 BARREL TWIN STICK CABLE 303309 1 CABLE ATLAS SHIFTER 48 LENGTH 1 TRAVEL 303311 HEAT SHIELD FIREPROOFSLEEVE 1 2 303311 HEAT SHIELD FIREPROOF SLEEVE 1 2 303312 BUSHING IGUS 3 8 303313 RODEND FEMALE 1 4 28 303313 RODEND FEMALE 1 4 28 303313 ROD END FEMALE 1 4 28 303341 BOLT 1 4 28 X 5 8 B H C S 303341 BOLT 1 4 28 X 5 8 B H C S 303342 SET SCREW 6 40 X 3 16 C P S S 303343 Access plug 303344 Pivot Dowel Pin Ground 2 25 303345 Sealant Butyl Tape 303346 BOLT 1 4 28 X 5 8 S H C S
6. Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI T P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 2 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 03 21 11 RUBICRAWLER JEEP TJ W NP231 amp NP241 The Igus bushings must be pressed into the shift handles A arbor press or a light hand with a hammer works well Once the bushings are installed the pivot pin gets Shifterassembly components installed through the handles with the wave washer between them Slide the pivot pin mounts over the pivot pin make sure the pivot pin is flush with the outside of the pivot pin mount Use the small set screw to lock the pin to the mount Check the orientation of the handles and set the handle assembly into the shift housing the one socket head bolt mounts the rear pivot pin mount to the housing and the other three holes use button head bolts SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we s
7. RE BRUSH CLEANING SOLVENT PAINT THINNER ACETONE MEK ETC DO NOT USE DEGREASERS LIKE SIMPLE GREEN STUBBY 9 16 WRENCH REQUIRED RATCHETING RECOMMENDED T20 T30 AND T45 TORX BIT SOCKETS AND A LONG T40 TORX BIT SOCKET 15 16 WRENCH 5 32 ALLEN WRENCH SLIDE HAMMER NEEDLE NOSE VICE GRIPS Note on new installations if the transfer case is re clocked up closer to the floor board we have had customers complain of vibrations in the drivetrain Clocking the transfer case changes the driveline angles which creates a vibration and most think it is because of the new RubiCrawler Re clocking the transfer case from stock will require axle pinion angle adjustments SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item
8. al pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 14 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Reassembly 1 Install the foot mount with the four supplied 10 mm hex head bolts and washers 2 Reinstall drive shafts and skid plates Transmission Fluid Re Fill Caution under filling or over filling can result in damage to yourtransmission Only use Mopar approved ATF 4 to refill the transmission Park ona flat surface and apply parking brake Start the engine and let the vehicle idle Apply the brakes and shift the transmission through all of the gears then back to NEUTRAL and leave thevehicleidling Check the transmission fluid level with the dipstick Using aclean funnel add ATF 4 transmission fluid until the oil level is between the two holes marked COLD Check to see if the transmission fluid level on the dipstick is even on both sides If one side is noticeably higher than the other the dipstick has picked up some fluid from the fill tube Allow the fluid to drain down the transmission fill tube and recheck Now thatthe fluid level has been approximately achieved drive the vehicle 5 10 mil
9. ble by adjusting the two 5 8 nuts so that the heim travels an 1 8 past the shift lever for both directions of travel See Figure 33 Attach the cable shifter heim to the previously installed shift lever See Figure 30 using the supplied 1 4 20x1 hex head bolt and anylock hex nut Reinstall the transfer case breather hose position switch and the vehicle speed sensor connectors Final Shift Lever Adjustment Figure 33 Transfer Case Cable Adjustment 1 Check the position of the levers through the console sees can be made by adjusting the cable barrels below the shifter box assembly For proper adjustment and adjusted clearance see Figures 34 amp 35 The transfer case shift lever should change to approximately 1 25 from the console after installation and final adjustment Figure 34 Proper Figure 35 Proper Adjustment Adjustment in Farthest with transfer case in 4Low and Forward Position the RubiCrawler in High SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manu
10. e Shifter Box Assembly End Cable Adjustment 1 Partially thread the RubiCrawler shift cable previously installed in step 12 into the passenger side barrel mount of the shifter assembly by rotating the cable barrels See Figure 18 Install the supplied heim joint completely onto the cable that was just mounted and tighten the 1 4 28 jam nut See Figure 19 Apply amedium strength thread locking compound to the 1 4 28x5 8 button head cap screw and bolt the heim joint just installed to the passenger side i shift lever See Figure 19 Figure 19 Bolt in Heim SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 8 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Re
11. e 26 Route the transfer case shifter cable through the lower transfer case shifter bracket hole with ajam nut on both sides of the bracket and then completely thread the heim joint on to the end of the cable and tighten the jam nut ote Figure 27 Cable Shifter Routing SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI T P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 10 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Figure 28 RubiCrawler cable shifter adjustment verification See Step 2 of the RubiCrawler Shifter Cable Gear Box End Adjustment SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type
12. ed method Make a custom device to span Figure 4 Pry Method the tailhousing without contacting the end of the shaft Thread a M10x1 5 bolt through tool and into the spud shaft See Figure 3 ii Pry Method fast but only works on some vehicles Use a piece of sheet metal to protect the tailhousing and bolt a large washer to the shaft Use a pry bar to pry the shaft loose taking care not to damage the SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 5 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 tailhousing See Figure 4 8 Prepare a drip pan Removing the tailhousing will result in 2 4 quarts of
13. es making sure to manually shiftthe transmission through all gears Recheck the fluid level with the transmission at operating temperature vehicle idling on flat ground the parking brake set and the transmission in neutral Add ATF 4 to raise the fluid level to a point be tween the two holes marked HOT Do this slowly so that the transmission fill tube has time to drain and gives accurate readings NOTE For proper operation of the RubiCrawler refer to the Shifting Procedure Warranty paper work and the yellow tag attached to the RubiCrawler case SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI T P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 15 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 10 26
14. nd machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ231A P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 12 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ 2003 2006 NON RUBICONS W TWIN STICK SHIFTERS Withthe transfer case still out of the vehicle remove the shift lever Install the new supplied shift lever with the original nut use a medium strength thread locking compound on the threads and see Figure 29 for correct lever orientation Torque to 20 ft lbs Figure 29 New Transfer Case Shift Lever Orientation NP231 SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do no
15. of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 11 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Figure 29 Shift Lever Removal Figure 30 New Transfer Case Figure 31 Proper Yoke with Needle Nose Vise Grips Shift Lever Orientation NP241 Installation Order This cable should already be routed under the transmission cooler lines See Figure 27 NOTE Ifyou purchased the optional Advance Adapters RubiCrawler Control Module PN 42R800 now is the best time to install it Refer to the RubiCrawler Control Module installation instructions for further information The stock studs from the transfer case are too long to bolt up to the RubiCrawler There are two options you can grind the end of the studs do
16. plain 340615 BOLT 1 4 20 X 5 8 B H C S 42R441 Bracket RubiCrawler cable mount 42R740 BOLT 8mmX 1 25 X 14mm H H C SNP241 42R460 BRACKET TJ HEAT SHEILD 42R706 KNOB NP231 42R617 BOLT 1 4 20 X 3 8 B H C S plain 1 42R708 LEVER TCNP231 42R700 SHIFTER BOX TJRUBICRAWLER THESE ITEMS ARE ASSEMBLED AND 42R701 PIVOT PINMOUNT ADJUSTED FOR THEINSTALLATION 42R702 BOTTOMCOVER 42R703 HANDLEMOUNT DRIVER SIDE 42R704 HANDLE MOUNT PASSENGER SIDE 42R705 KNOB TJRUBICRAWLER 42R709 SPRING WAVE 42R715 BARREL CABLETJ RUBICRAWLER 42R725 1 9 SHIFTER CABLE 2 TRAVEL 42R730 BRACKET T CASESHIFTER 42R735 BOLT 1 4 20X 1 H H C S Grade 8 42R740 BOLT 8mm X 1 25 X 14mmH H CS zinc 42R745 PLUG7 16 BLACK 720057 6mm X 1 00X 16mm H H C S GRD 8 8 zinc 722513 LOCKWASHER 1 4 PLT 722514 NYLONLOCKNUT 1 4 20 722523 1 4 USS FLAT WASHER PLTD 723753 F H C S 3 8 16 X 1 1 4 42R707 LEVER TJNP241 TCASESHIFT 42R710 SHIFT KNOB TJ241 PNNABRNR KF NY A Nn ce ee NNE A A ey e e e e e Nee U me m UW SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of
17. ssion lubrication circuits Liftthe RubiCrawler into place rotate the output shaft until the splines line up and the RubiCrawler slides on make sure it slides on by hand far enough to squish the RTV Fasten the RubiCrawler with the 10 supplied 10 mm socket head cap screws using an 8 mm hex bit socket and the 10mm button head cap screw that bolts on under the shifter box using a6 mm hex bit socket The supplied heat shield bolts on below the two lower passen ger side bolts which can be seen in Figure 25 Torque all bolts to 40 ft lbs RubiCrawler Shifter Cable Gear Box End Adjustment 1 Install the RubiCrawler shifter bracket to the flange of the RubiCrawler case using two 8 mm bolts and 1 4 washers supplied with the kit Verify that the RubiCrawler cable travels an 1 8 past the mounting hole on the RubiCrawler shift lever for both directions of travel Use ie a acrescent wrench to shift the RubiCrawler while rotating the output j shaft See Figure 28 i Using amedium strength thread lockingcompound and the supplied PECORE OE i 1 4 28x5 8 button head cap screw bolt the heim joint of the RubiCrawler shiftcable tothe RubiCrawler shift lever Figure 26 Transfer Case Shifter Bracket Transfer Case Installation and Transfer Case Shifter Cable Gear Box End Adjustment 1 Boltthe transfer case shifter bracket to the side of the RubiCrawler shifthousing using the supplied 6mm hex head bolts and 1 4 lock washers See Figur
18. t fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment ese manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 13 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Lubricate the lip seal on the back of the RubiCrawler with ATF 4 Shift the transfer case into any gear other than neutral The RubiCrawler has amachined mark that designates the stock rotation hole set or refer to Figure 32 Install the transfer case back into the vehicle by lifting it into place and rotating the rear yoke until the splines engage Start all nuts before fully indexing the transfer case in to the RubiCrawler Note Do not forget to refill the transfer case if any fluid spilled 7 Makesure that you do not pull the transfer case on by tightening the nuts push iton completely first by hand Use a stubby 9 16 wrench to torque the transfer case nuts to 25 30 ft lbs E E Adjust the transfercase shifter ca
19. t return the product as furthet described below All returns must have a returned goods authoriztion RGA prior to shipping the product and returns are to be sent prepaid freight Please call 1 800 350 2223 and the sales department can assist you Warranty will be voided if the proper transmission fluid levels are not maintained if any transmission fluid other than ATF 4 is used or the product has not been properly installed and instructions have not been followed SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores
20. til it pops off Usingasmall flathead screw driver remove the transmission shiftindicator cover Once it pops loose you must disconnect the light onthe bottom side of the cover to completely remove Figure 8 Cup Holder Removal SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of conversions Modifications to any of the components will void any possible warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P O Box 247 4320 Aerotech Center Way Paso Robles CA 93447 P N RUBI TJ New Item 9 09 PAGE 6 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date RUBICRAWLER JEEP TJ W NP231 amp NP241 it See Figure 9 and 10 Use a 10mm socket to remove the twoconsole bolts located under the cup holder and under the shift indicator panel Movetransfercase handle to 4wd Low and then pull the console out Usingaflathead screwdriver remove the wire loom con
21. ting diagrams and other related equipment ee eee cs eee ee eee ADVANCE ADAPTERS INC P N RUBI TJ P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 16 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 10 26 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 4 an Ruicrer TJ Non Rubicon Knob sora RA ene ont be Pa Fore fi ae Shift mi i TE ait time l TJ Shift Knob Maximum Speed The Rubi Crawler should not be operated at engine speeds above 5000rpm when the transmission is in overdrive This over speed condition will cause damage to the bearings and geartrain in the RubiCrawler in addition to possible damage to other components in the TJ Rubicon Knob ye ADVANCE ADAPTERS INC LIMITED WARRANTY The RubiCrawler is guaranteed against defects in workmanship and materials for one year This warranty begins from the date the unit is shipped from Advance Adapters We log all units with a serial number at time of shipping The wannanty is void as determined by Advance Adapters Inc by misuse abuse improper mainenance or installation and or alterations to the product These guarantees do not cover any outside labor shipping towing normal wear or any other unforseen events that that may occur due to failure of a unit Advance Adapters reserves the right to repair or replace any product Do not disassemble or attempt to repair the RubiCrawler as doing so will void the warranty jus
22. transmission fluid loss depending on the angle of the drivetrain 9 Remove the transmission tailhousing by removing the 11 hex head bolts See Figure 5 10 Allowoiltodrain for 10 Figure 6 Rag Placement minutes Figure 5 Transmission 11 Inserta CLEAN shop rag into the back of the transmission as shown in Tailhousing the picture below to prevent contaminates from entering your transmission See Figure 6 12 Thoroughly clean the rear face of the transmission Use solvent and abrass wire brush to clean all of the RTV off of the mating face and take caution to avoid any debris from entering the transmission or transmission bearing It may be necessary to trimexcess RTV that protrudes up from the transmission pan onto the rear face of the transmission See Figure 7 Excess RTV can prevent the Rubicrawler from fully mating to the transmission face 13 Remove the spud shaftretaining clip from the groove near the end of the transmission output shaft Interior Disassembly Reassembly 1 Disconnectthe negative terminal of the battery 2 Remove the drivers seat Unbolt the four mounting bolts using a T 50 torx bit and a 13mm socket Tilt the seat back and disconnect the plug connected to the under side of the seat Remove the seat from the vehicle Remove the cup holder ifitis removable depending on the style of your console See Figure 8 Removethe transmission shifthandle by grabbing firmly and pulling straight up un
23. trongly recommend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of Advance Adapter components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These manuals are normally available at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI T P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 3 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 03 21 11 RUBICRAWLER JEEP TJ W NP231 amp NP241 Remove the double nuts on one end of the cable and install the heat shield reinstall one of the nuts and the star washer Take the long barrel retainer and slide the retainer on it verify the retainer is orientated correctly to bolt to the shifter body Thread the barrel onto the cable and then install the heim joint to the cable end Tool List 1 FULL SET OF HAND TOOLS INCLUDING 6 mm ALLEN WRENCH 16 mm DEEP SOCKET 8mm HEX BIT SOCKET 3 8 DRIVE RATCHET 15 16 WRENCH ae 5 32 ALLEN WRENCH Install the short cable barrel and then mount to the shifter 3 8 TORQUE WRENCH housing Aline the heim joint with the access hole on the 25 TO 40 FT LBS REQUIRED shifter housing and the handle then bolt together with the GASKET SCRAPER button head bolt The plastic cap can be installed after 4 SMALL BRASS WI
24. v Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Rotate RubiCrawler cable barrel until the shift knob lines up with the edge of the cup holder in its furthest back position see Figure 20 Verify that the RubiCrawler shift lever does not contact the console in its furthest back position Installthenylon access plug to the passenger side of the shifter box assembly Rotate the transfer case cable barrel until the center of the knob is 1 from the console when in its lowest position See Figure 2 7 Tighten the three 1 4 28x5 8 Figure 20 RubiCrawler Shift bolts that retain the cable barrel Knob in Furthest Back Position retaining clip See Figure 22 8 Usinga 15 16 wrench tighten __ the 5 8 jam nuts on the shift cables 9 Boltonthe bottom cover of the shifter box using the supplied 1 4 20x3 8 button head cap screws NOTE Make sure you start all 3 before final tightening UseRTV fi tit Ghia ee X F igure 22 Tighten Re Figure 21 1 from console l H if RubiCrawler Installation 1 Remove the red plug and O ring from the RubiCrawler as seen in Figure 23 Remove the rag from the transmission and discard the red plug The RubiCrawler should be test fit into the vehicle by installing it without RTV to make sure the RubiCrawler flange face touches the transmission face completely This is to insure that the output shaft is not too long The product was designed for a standard output shaft stick out
25. vailable at automotive dealerships and parts stores ADVANCE ADAPTERS INC P N RUBI T P O Box 247 4320 Aerotech Center Way New Item 9 09 Paso Robles CA 93447 PAGE 7 of 16 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 1 11 10 RUBICRAWLER JEEP TJ W NP231 amp NP241 Apply butyl tape around the perimeter of the shifter box as shown in Figure 15 Withthe aid of another person install the shifter box assembly ensuring that the transfer case cable is routed under the transmis sioncooler line See Figure 16 A Figure 15 Apply Butyl Tape 15 Boltthe shifter box assembly downusing an 8mm socket and the 5 ___ stockOEM boltsremoved previously 16 Move the transmission shifter into the Neutral position with the twin stick handles in the vertical position Point the front of the console towards the passen ger side then rotate the console CCW as you maneuver it down over the twin stick handles and transmission shifter Boltthe console down using a 10mm socket and Figure 16 Shifter Box the two bolts removed earlier Install the Assembly w T Case Cable shiftindicator back on tothe console Fi igure 1 a Console Install making sure to plugin Transfe the indicator bulb before snapping it back in to place See Figure 17 Install the new shift knobs using the supplied 3 8 16x1 1 4 flathead cap screws The transfer case knob mounts on the driver side andthe RubiCrawler knob mounts on the passenger sid
26. wn 3 16 to the first thread or you can remove the stock studs and use the studs supplied If you grind the studs make sure to protect the input shaft area from debris NP241 units only With the transfer case still out of the vehicle remove the shift lever The torx bolt retaining the stock shift lever is difficult to access due to front yoke clearance Two recommended meth ods for removing the bolt i Use long needle nose vise grips to grab the head of the bolt and attempt to loosen See Figure 29 ii Usean 1 1 8 socket and impact gun to remove the yoke nut and yoke Do not allow any contaminants to enter the transfer case while the yoke is off Use a long T40 Torx bit and remove the shift lever bolt and then the shift lever Toreinstall the yoke install anew rubber yoke washer Chrysler PN 04210973 in to the yoke splines Apply a bead of silicone to the inside of the yoke Apply ATF to the lip of the yoke seal slide yoke over the rubber washer until it bottoms out in the case Secure using a new yoke nut Chrysler PN 04167924 this is very important as the yoke nuts are designed for one time use and torque to 110 ft lbs See Figure 31 Install the new supplied shift lever with the supplied M8 1 25x14 hex head bolt and 1 4 washer use a medium strength thread locking compound on the threads and see Figure 30 for correct lever orientation Torque to 20 ft lbs SPECIAL NOTE The components packaged in this kit have been assembled a
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