Advance Adapters SYE Install docs
Contents
1. lbs 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 9 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 05 03 01 NP231 SHORT SHAFT FIXED YOKE KIT Fig 10A Bearing Installed Fig 11A Seal and Retained with the 716464 Installed Fig 9A Speed o Ring Gear Install Snap Ring 8 Assemble speed o drive 10 Short Tailhousing Installation a Install retaining ring located just behind the pump a Prelube bearing amp seal in new shorttailhousing assembly b Slide ring gear into position Fig 11A c Install retaining ring behind ring gear Fig 9A b Apply sealantto tailhousing mating surface of rear case thin film c While supportin2. by a worn or stretched drive chain You will need to be the judge 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 6 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 05 03 01 NP231 SHORT SHAFT FIXED YOKE KIT New Process 231 transfer cases have used two types or styles of output shafts The current style New Process output shaft started to be used in 1997 and is still being used This newer style shaft eliminated the caged needle bearings in the drive sprocket We have designed our Heavy Duty fixed yoke output shaft kit with the most current design shaft found in the New Process 231 transfer case Our shaft looks like the shaft below left li
3. if needed Fig 5 Fig 6 Rear O D Snap Ring Removal Fig 8 Rear Tailhousing Removal 9 Remove rear bearing retaining rings Fig 6 amp Fig 7 10 Remove tailhousing bolts with 10mm socket amp remove tailhousing Fig 8 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 5 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 06 24 02 NP231 SHORT SHAFT FIXED YOKE KIT A Fig 11 Front Drive Chain amp Shaft Removal Fig 9 Rear Case Half Removal 11 Remove the rear case bolts A 10mm 12 pt socketis needed 14 Frontoutput shaft removal forthe spline head bolt amp a 15mm socket for the remaining bolts a Pullthe front outpu
4. ADVANCE ADAPTERS INC P N 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 1 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 06 24 02 NP231 SHORT SHAFT FIXED YOKE KIT KIT CONSISTS OF Qty Part No Description 51 7905 TAILHOUSING DIECAST 1 1 52 7905 SHAFT MAIN OUTPUT 1 300474 SEAL WASHER REAR YOKE 1 300475 YOKE C V REAR 1 300476 NUT REAR YOKE 1 300480 SEAL WASHER FRONT YOKE 1 300625 RING GEAR SPEED O 2 1 1 1 1 300627 SNAP RING SPEED O RING GEAR 716318 BEARING 207 OPEN BALL No Snap Ring 716464 SNAPRING 207 BEARING 716465 RETAINER RING MODE 716751 SEAL TAILHOUSING CHADKWRWHN Hy SPECIAL NOTE Onvehicles that have the vacuum actuator on the tailhousing we offer a different tailhousing that will provide you the necessary vacuum actuator connection P N 51 7906 can be exchanged for 51 7905 The shift rail must be shortened to protrude 1 when in 4WD low or 4WD high INSTALLATIONPROCEDURES Every effort has been made to make sure your kit fits and works right the first time However if you happen to experience a problem with your kit please contact us by our toll free technical assistance line at 800 350 2223 Monday through Friday 8 00 a m to 4 00 p m PST The installation of this kit requires you to nearly disassemble the entire transfer case If your transfer case is in need of a rebuild now is the perfect time to do
5. PECIAL 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 Telephone 800 350 2223 P N 50 7905 New Item 12 98 PAGE 3 OF 10 Fax 805 238 4201 Page Rev Date 06 24 02 NP231 SHORT SHAFT FIXED YOKE KIT DISASSEMBLY Fig 1 Yoke Nut Removal Fig 3 Slinger Removed Harmonic Dampener Remove the output shaft boot Spread bandclamps with a Awl Slide boot off Remove slinger this one is tough Good thing you won tneed this later Fig 3 Onnewertransfer cases Jeep used aharmonicdampener The dampener has 3 tapped metric holes By installing the bolts into Remove Speed o drive Remove front yoke nut a Move range lever to 4L position b Remove front yoke nut with 1 1 8 socket using an i
6. Robles CA 93447 Telephone 800 350 2223 3 6 SPECIAL NOTE Fax 805 238 4201 P N 50 7905 New Item 12 98 PAGE 8 OF 10 Page Rev Date 05 03 01 NP231 SHORT SHAFT FIXED YOKE KIT Fig 5A New Main Output Shaft Assembly Output shaft and drive chain assembly Lubricate chain amp shaft with ATF Insert main shaft assembly into the housed planetary assembly Install the drive chain onto the front output shaft Insert them into the bearing Lift upward and tilt the shaft toward the main shaft to work the chain into position Fig 5A Make sure the mode spring is in place seen in the middle Fig 5A Fig 6A Case Half Pre assembly Rear case assembly a Withallcomponents clean install oil pump b Seat the pickup tube into the pump o ring Fig 6A c Prelube the front output shaft bearing located in the rear case Apply a thin film of sealant to the front case Use a good RTV like the OEM sealant available from your local Jeep dealer Fig 7A P N 82300234 7 Fig 7A Thin film RTV Applied Prior to Mating Case Halves Fig 8A Case Halves Assembled Assembly of case halves Fig 8A a Slide the pump amp case into position Ifyou have difficulty check for possible problems DO NOT FORCE Mode fork rail extends through rear case c Installall fasteners in their original positions Black bolts at dowel locations d Torque evenly to 27 34 N m 20 25 ft
7. et Needle Bearings Fig 3A New Main Output Shaft Assembly 1 These bearings must be removed Once the bearings are 2 Mainshaftassembly removed clean the inside of the drive gear to make sure itis free a Cleanallcomponents of any type of debris A On 1997 and newer transfer cases the drive sprocket b a a Assembly lybricant does not use caged needle bearings If you have this newer style then continue on to Fig 3A 2 c Slide drive sprocket into position d Slide mode hubinto position e Install the retaining ring into position after the mode hub Fig 4A Fig 2A Pull the Needle Bearings Out Fig 4A Large Retaining Ring Installation 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
8. g main shaft slide new tail assembly into position d Use care when indexing pump outer tabs and aligning tail assembly for installation Fig 12A NOTE Pull back on the output shaft to seat it against the rear bearing e Install the 5 10mm bolts that retain the tailhousing and torque evenly to 20 27 N m 15 20 ft Ibs NOTE On some NP231 transfer cases the shift rail must be shortened This shift rail protrudes out of the transfer case and goes into the tailhousing The newtailhousing has a pocket depth of 1 125 Shift your transfer case so the shift rod is protruding the furthest out of the transfer case If this shifter rod protrudes more than 1 out of the back side of the transfer case then the shift rail must be shortened Transfer cases that will normally require this rail to be shortened measure 1 5 photo above left Using a hack saw or cutoff wheel and safety glasses trim the shift Fig 12A Tailhousing Installation rail shaft so that it protrudes only 1 photo above right 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 t
9. he 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 10 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 05 23 03 NP231 SHORT SHAFT FIXED YOKE KIT Figures 13A Final Installation 11 Yoke amp Seal Washer installation This will apply to both Front amp Rear yoke assembly a Slide the yoke seal into position on the shaft thread b Lube the yoke as well as the seal with ATF c Alittle trick to keep the spline seal in good shape is to slide the yoke half way on and walk the yoke into position with the retaining nut Torque to 140 150 ft lbs with 1 1 8 socket d Install your stock speedometer housing into the new tailhousing Depending on which speedometer gear tooth count you are using will determine the proper rotation of the speedometer housing Each housing has 4 possible rotation options Identify you speedometer gear tooth count and locate that tooth count on your speedometer housing The number range on your housing will need to be lined up with the housing retaining clip see photo Atouch of RTV Blue silicon around the o ring will help seal the housing to the ta
10. ilhousing 12 Filltorecommended level with ATF 13 Reconnect all exterior items driveshafts 4WD switch speedometer cable etc 14 Happy Trails 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
11. it To install this kit it is easier to remove your transfer case and set it on end upon a workbench but it is not necessary Here area couple of points to keep in mind that will make the installation much easier if you ve never disassembled a New Process transfer case Keep all bolts nuts washers etc separated into groups as you remove them Make sure you keep them in a labeled container that indicates what part of the transfer case they came from Keep all small parts in separate containers and label as to location and origin Make sure you have plenty of time and a clean spacious area to perform the installation THINGS TO CONSIDERBEFORE YOUBEGIN 1 This kit is shipped with a rear 1310 series C V type yoke You will need a C V equipped driveshaft 2 Medium strength thread locker is recommended on all threaded fasteners 3 A sealant such as RTV like the OEM sealant is needed and is available from your local Jeep Dodge dealer P N 82300234 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 recom
12. mend 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 2 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 03 04 02 NP231 SHORT SHAFT FIXED YOKE KIT DRIVE SHAFT MODIFICATION This job should be performed by a local driveline repair shop capable of balancing the finished assembly Use a C V joint amp long slip spline style shaft assembly With the vehicle finished and on the ground measure a straight line between the transfer case output yoke and the rear pinion yoke center mating flanges Fig A Listed below are a few sources of driveshaft manufacturers amp suppliers Six States Distributors UT 1 800 453 2022 Mountain Driveline AZ 1 620 244 8115 Tom Woods Custom Driveshafts 1 877 497 4238 High Angle Driveline CA 1 530 877 2875 Fig A For proper C V type drive shaft operation the rear differential should be pointed at the transfer case output yoke under normal driving load If install is performed on jack stands make sure you have supported the vehicle well Place the transfer case range selector in the 4L position Remove front amp rear drive shafts and begin at the disassembly procedures Step 1 Fig 1 S
13. mpact wrench Fig 1 Remove yoke Note If difficult use a puller Discard seal washer Remove selector lever Fig 2 these holes they will go through the dampener and press against the stock tailhousing pressing the harmonic dampener off the output shaft Remove stop spacer amp snap ring Fig 4 Fig 2 Range Selector Removal Fig 4 Stop Spacer amp Snap Ring 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 N 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 4 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 07 27 99 NP231 SHORT SHAFT FIXED YOKE KIT Fig 7 Rear I D Snap Ring Removal Fig 5 Rear Seal Removal 8 Remove rear seal Collapse with punch
14. sted as TJ style Jeeps having the earlier style output shaft listed as YJ style can use this kit by simply removing the caged needle bearing from the stock drive sprocket TJ style shaft sp YJ style shaft Current NP231 shaft design z Early style NP231 shaft design and our kit design No needle t d The caged needle bearing from the bearings required drive sprocket must be removed for proper installation on our output shaft 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 50 7905 P O Box 247 4320 Aerotech Center Way New Item 12 98 Paso Robles CA 93447 PAGE 7 OF 10 Telephone 800 350 2223 Fax 805 238 4201 Page Rev Date 05 03 01 NP231 SHORT SHAFT FIXED YOKE KIT New Shaft ASSEMBLY CONSIDERATIONS Fig 1A Drive Sprock
15. t shaft out of the front bearing Fig 11 nae ir A i m A sells atthe case b Slide drive chain offthe rear output shaft and remove both shaft and chain for cleaning amp inspection Start to remove the rear case from the front case by inserting Rearoutputshaftremoval pry bars atthe cast in locations ONLY Fig 9 p a Grasp the main shaft and remove the shaft drive sprocket a Pry apart evenly to break the sealer bead along the case and mode hub assembly mating surfaces Fig 10 The oil pump pickup tube is not accessible from the back of the case until the back half of the case has been taken off far enough to disengage the pump drive splines on the stock output shaft At that time you can either slide the pump up on the housing and remove the pump pickup tube or just remove the pump and pickup tube complete with the rear case half a Inspectthe pickup tube o ring inthe pump and replace if needed The same goes for the front shaft seal in the pump Do NOT disassemble the pump itis nota serviceable item b Remove clean and inspect the inner case for wear Fig 12 Front Drive Chain amp Shaft Removal Output shaft disassembly a Remove the mode hub retaining ring with heavy duty snap ring pliers Fig 12 b Slide remaining components mode hub amp drive sprocket off shaft 17 Thisis as far into the case you need to go unless you find foreign Fig 10 Oil Pump Removal material inside usually caused
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