Installation Instructions - Omix-Ada
Contents
1. k P P k 5 Remove these cage bearings if fas equiped Early NP231 s Drive Sprocket Drive Chain STEP 8 Be sure all parts are clean and serviceable Prelube all parts before installation Place the mode hub sprocket and retaining ring into position on the new shaft NOTE you may need to remove cage bearings from the drive sprocket on early NP231J See diagram above These bearings will not be needed Discard m n M EE mA Photo 3 Mode hub drive sprocket and retaining ring positioned on the new main shaft These parts are now ready to re install AGAIN Early model 231 s might require the removal of the needle bearing cage from the drive sprocket before it can be installed Discard needle bearing cages as they are no longer needed STEP 9 With the case disassembled inspect the mode fork shift rod see image above If the shift rod measures 10 2 than you will need to cut it down to a length of 9 380 This has been found to be a common problem for 1988 1989 YJ models You will need to cut the shift rod at the end located on the back side of the transfer case Yoke side Make sure that after cutting all burs and ruff edges have been cleaned Mode Shift Fork Rod Should measure 9 380 long Pg 4 Rugged Ridge Installation Instructions 18676 72 STEP 10 Lubricate the shaft assembly chain and shaft bearing surfaces Install the main shaft assembly into the fr2. Mega Short Slip Yoke Eliminator Kit For NP231 Part Number 18676 72 Ihe following parts are supplied with this kit D Mega Short output shaft li short output shaft housing 15 Output Y oke with pre installed seal heanng and 15 Magnetic Speed Sensor C clip nne 1 Speed Sensor retainer bolt r4 Outpt Yoke UNF 12 point bolts rd Output Yoke UNF flat washers 15 output Yoke retainer nut 1 Tone Ring waling holes li speed Sensor retainer bolt wiwasher The 18676 72 kit has been designed to work with all Wranglers and XJ Cherokees with an electronic speedometer and a factory installed NP231 J transfer case Any vehicle manufactured prior to 1992 will need to be retro fitted with an electronic speedometer will not work with cable driven speedometers Not Available through OMIX ADA or Rugged Ridge APPLICATION NOTES 1 Some early NP231 produced from 1987 1990 have the vacuum switch for the front axle disconnect located in the rear output shaft housing This kit is supplied with a new housing that does not allow for the vacuum switch to be reused for this applications It will be necessary to purchase a cable operated disconnect manufactured by 4x4 Posi Lock or replace the front passenger side axles with later solid axle shafts 2 Some 1998 and older model Jeeps will have a different three wire connecter than what is supplied with this kit If this is the case you will need to hard wire the leads to eliminate the c
3. 1957 05 WRANGLER 1967628 MODE SHIFT FORE PAD EIT 1267624 Pg 10 OUTPUT SHAFT REAR OIL SEAL 1957 95 WRANGLER SHIFT MODE SELECTOR 1997 89 WEAH GLER SHIFT MODE SELECTOR 1991 93 WRANGLER SHIFT MODE SELECTOR 997 99 WRANGLER MODE SHIFT FORE BUSHING 1937 95 SELECTOR SHAFT 0 SELECTOR SHAFT SEAL SHIFT MODE SYHCHEUHIZEREBLOCEIHC RING 1927 05 WEAH GLEF FROHT OUTPUT YORE HOT 1237 99 ER OUTPUT YORE CHEROEEE FROH TOU TPUT YORE GRAND FROM T OUTPUT YORE 1227 95 WRANGLER FROH TOU TPUT YORE 1997 9 WRANGLER FROM TOU TPUT YORE WASHER 1997 95 WEAH GLEF YOEE STRAP amp BOLT KIT 1937 35 WEAHGLEF FRONT OUTPUT SEAT OUTPUT MAIHDEIVE SPROCKET BEARING 2 needed 1927 89 WRANGLER MAIHDEIVE SPROCKET BEARING 2 needed 1991 95 WRANGLER MAHD RIVE 1987 95 WRANGLER OIL PUME HOUSING OIL SEAL 1987 99 WRANGLER OIL PUME HOUSING 5 OIL SEAL 1987 99 WRANGLER REAR OUTPUT SHAFT OUTER BEARING 1997 99 WEAH CLEF OUTPUT SHAFT FRONT BEARING 1997 99 WEAH GLER FRONT OUTPUT SHAFT 1987 99 WEAT GLEF HEW PROCESS 2231 1987 04 WEAHDCLEE HEW PROCESS 231 1987 01 CHEROKEE HEW PROCESS 231 1993 96 GRAND CHEROKEE OUTPUT SHAFT FEAF BEARING 1927 99 WRANGLER REAR OUTPUT SHAFT SLIP YORE 1937 93 WEAH GLEE SILICONE TUBE use as gasket YORE FOR SLI YOKE ELIMINATOR EIT SPEEDO GEAR HEW PROCESS 241 DODGE PICE UP OIL SEAL USED IH SLIP ELIMINAT
4. shaft assembly to avoid problems with lifted vehicles If you wish to have a custom driveshaft fabricated you will need to get your new driveshaft measurement length Use the measurement procedures listed in step 18 Note for proper C V type drive shaft operations the rear differential oke should be pointing at the transfer case output yoke This should be checked under normal driving conditions and load STEP 19 Speedometer Calibration Data Proper calibration of the speedometer will greatly depend on what changes have been made to the axle gear ratio and tire size There are some combinations that will not require calibration changes refer to the chart below and are shown in the color gray The other data reflects what your speedometer percentage of error will be if the speedometer 15 not recalibrated If your vehicle requires recalibration a converter box be purchase Not Available from Omix Ada Rugged Ridge Rugged MSAN E 8 19 19 20 22 IL mp 10 10 1196 14 19 12 9 25 18 14 ET 40 37 35 35 32 31 30 29 28 27 Pg 7 Rugged Rid ge Installation Instructions 18676 72 The following information will be used if working with a 1998 and older NP231J s equipped with different connector design than what has been supplied in this kit For the installer to use the Rugged Ridge 18676 72 MSSYE Kit in vehicles older than 1999 it may be necessary t
5. steps of the disassembly process oil pump pickup tube may need to be removed before the case halves can be split Pg 2 Rugged Ridge Installation Instructions 18676 72 STEP 5 Mark the locations of the rear case half bolts before removing them Start the case separation process by using the cast in pry bar location slots only Prying anywhere else on the case halves may create an uneven surface that will not seal properly when reassembled Carefully begin to pry the case halves apart Some models will be able to remove the pickup tube and pump assembly with the rear case NOTE Inspect the pickup tube o ring and the front shaft seal in the pump Do not take the pump apart it is not serviceable Photo 2 NP231 with the rear case and oil pump assembly removed Clean and inspect all parts STEP 6 Remove the front output shaft Remove the chain from the main shaft Clean and inspect the chain and gears STEP 7 Remove the main shaft from the front case Make note of the locations of the snap rings mode hub and sprocket of these items will be positioned on the new shaft NOTE On many earlier models the sprocket used two caged needle bearings These bearings will need to be removed in order for the sprocket to be installed on the new shaft DISCARD cage bearings no longer needed Pg 3 Rugged Installation Instructions 18676 72 OE im Shaft 9 1 uim 4 x b
6. OR EITIN HP231 SPARE HARDWARE EITFOR 1857650 SLIP YORE ELIMINATIE SPEED SEH S0R FOR 18676 72 MEGA SHORT EIT FEMALE COUPLING FOR 1998 OLDER HP231 SHAFT BEARING FETAIHEFE pn 19676 29 pin 19676 20 pin 1867631 pin 19676 22 1567 6 49 1867633 pin 1967624 pn 12076 35 pn 1907636 pAn 1 676 33 pn 1 676 39 18070 27 19076 37 pA 15676 40 pn 16567 03 pA 1676 41 pin 14074 47 pn 12676 43 12676 44 Pen 13676 45 Pen 18676 46 pA 12076 47 1 676 4 pn 19076 47 pn 19076 50 1261201 pn 15617 01 pn 1 617 01 Pen 12076 51 165 0 53 pn 19701 401 pn 18676 61 pA 12077 01 pA 12076 02 18876 64 pA 12676 71 1 676 73 Rugged Ridge LIMITED 6 MONTH or 6 000 MILE WARRANTY Applies to Rugged Ridge by Omix ada Inc Products Rugged Ridge Off Road the Company warrants to the original purchaser of this product that should the product or any part thereof under normal use and conditions be proven defective in material or workmanship within 6 months or 6 000 miles which ever comes first from the date of original purchase such defect s will be repaired or replaced or credited at the Company s sole option To obtain repair or replacement within the terms of this Warranty the product is to be delivered with proof of warranty coverage e g Dated bill of sale specification of defect s to the place of purchase o
7. PUT GEAR 25 SPLINE WRANGLER WICASE A S 3008210 52097893 OR 52098042 UNITS pac 1867647 IHPUT GEAR 23 SPLINE CHEROKEE WICASE KS 3008210 52097893 OF 52098042 UNITS pac 1867647 IHPUT GEAR 21 SPLINE WRANGLER 19676 06 IHPUT GEAR 21 SPLINE pin 1967608 IHPUT GEAR 23 SPLINE WRANGLER 19676 09 IHPUT GEAR 93 SPLINE pan 1967609 IHPUT GEAR 25 SPLINE GRAND CHEROKEE 18676 09 IHPUT GEAR 23 SPLINE GRAND CHEROKEE Wi 52097526 CASE pin 15676 10 IHPUT GEAR INNER BEARING 1987 99 WEAH GLER pr 1257611 DRIVE SPROCKET 1987 03 WRANGLER pn 19676 12 DRIVE SPROCKET 1997 99 WRANGLER pn 19676 13 VACCUM SWITCH 1987 93 WRANGLER pin 12676 14 ELECTRICAL PNDC SWITCH 1997 02 WRANGLER pin 19676 15 CASE DOWEL 2reeded 1997 99 WRANGLER pre 19676 16 RANGE SHIFT FORK 1987 90 WRANGLER EXCEPT 53008210 11 12 UNITS ph 1967617 RANGE SHIFT FORE BUSHING 2needed 1987 93 WEAH GLER wn 167618 SHIFT MODE SYHCHE OHIZER ASSEMBLY 1987 03 WRANGLER favo bleckngrmg pn 1867619 RANGE SHIFT HUB 1987 80 WRANGLER pin 19676 20 RANGE SHIFT HUB 1988 95 WRANGLER pin 1867621 RANGE SHIFT HUE 1997 99 WRANGLER pin 18676 27 RANGE SHIFT FORE PAD SET 1987 90 WRANGLER 18676 23 RANGE SHIFT FORE PAD 1991 99 WRANGLER pin 18676 24 HOUSING CASE REAR EXTENTION 1987 05 WEAH GLER ph 18676 25 MODE SHIFT FORE 1987 93 WRANGLER pin 19676 26 MODE SHIFT FORE 1997 99 WRANGLER 19676 27 MAINZHAFTEEAE BUSHING
8. Tone ring should have the tall edge facing towards the back of the transfer case and the flanged side short edge should be facing the yoke threaded side of the main shaft STEP 14 Clean the mating surface of the transfer case and the Mega Short output housing before proceeding Pre lube bearing and apply ATV to the output housing NOTE the housing should already have the bearing seal and bearing C clip ring installed by the factory With all components in place install the Mega Short output housing reusing the OE bolts used to hold the factory output housing in place Pg 5 Rugged Ridge Installation Instructions 18676 72 WARNING If you experience difficulty installing the Mega Short output housing check to make sure you have properly installed the speed sensor tone ring in accordance with step 13 The outer edge of the sensor is sloped and must match the angle of the speed sensor pickup when installed STEP 15 Pre lube the surfaces on the yokes where both the inner and outer seals will be Slide the yokes on and tighten the retaining nuts to 170 180 ft lbs STEP 16 Install the Magnetic speed sensor into the Mega Short output housing It is important to use a small amount of oil or ATF on the o ring to insure easy installation and avoid splitting and breaking the o ring Hand tighten the sensor retainer bolt and washer Torque to 7ft lbs DO NOT OVER TIGHTEN damage may occur to sensor STEP 17 Reinstall the transfer case into
9. itional worn parts now would be the time to do so 2 Obtain a service manual for your Jeep This will provide illustrations and information regarding parts identification torque values and other important data 3 Use photos and notes mark and label all parts for future reference 4 Keep all bolts nuts washers ect separated into groups as you remove them Place inside zip lock bags and mark location removed from 5 Make sure you have all the required tools pre lubricants sealant OEM part number 82300234 thread locker and a clean work area 6 Make sure you have the time needed to perform this conversion without being rushed STEP 1 Remove the transfer case from the Jeep Drive shafts speedometer drive unit linkages etc must be removed The case must be separated from the transmission Refer to your service manual for details STEP 2 Remove front yoke nut and yoke Shift the range lever into the 4 Low position Remove the selector lever All of these parts will be re used STEP 3 Remove the output shaft boot and dust shield Some newer models may have a harmonic balancer There may be other slight model variations Refer to your service manual for details STEP 4 Remove the spacer and snap ring Remove the seal inner snap ring on the shaft and the bearing retainer ring Remove the output housing bolts and then remove the existing output assembly Photo 1 NP231 after completion of the first four
10. k Signal Ground fa ba Digital Vout White or enr Speed signal Speed Sensor p n 18676 7 1 Brown or White Black Cut wire leads here Rugged iV Ridge Parts Breakdown 18676 72 The following parts are supplied with this kit 1 Mega Short output shaft 1 Mega Short output shaft housing 1 Output Yoke with pre installed seal bearing and 1 Magnetic Speed Sensor C clip ring 1 Speed Sensor retainer bolt 4 Output Yoke UNF 12 point bolts 4 Output Yoke UNF flat washers 1 output Yoke retainer nut 1 Tone Ring w oiling holes 1 Speed Sensor retainer bolt w washer Mega short output shaft Mega short output housing Output Yoke w bearing seal and retaining c clip ring p b Y E 2 lis oke retainer nut UNF 1 2point yoke bolts E 7 1 a i bearing oiling ports Tone ring w eight Pg 9 Fe el Ll bo bo Ln 4 fe M2 cO Ch Ch Rugged i Ridge NP231J Parts List OMIX ADA IHPUTEEARIHG EIT 1987 95 WEAH GLER mehdes bearing amp seal pn 12676 41 IHPUTEEARIHG RETAINER SEAL 19087 00 WRANGLER pin 18676402 INFUTBEARING RETAINER SEAL 1990 99 WRANGLER 1867643 GEAR OUTER BEARING 1987 95 WRANGLER pin 18676 04 INFUT GEAR OUTER BEARING 1997 99 WRANGLER pn 18676 05 IHPUT GEAR 23 SPLINE 1997 99 AUTOMATIC WRANGLER inchides bearing pin 1967606 IH
11. o cut both connector leads to hard wire into the vehicles wire harness Wiring diagram shows the correct color code needed to splice wires Cut wires located directly after the female and connector located on the chasse of the vehicle and on the new 18676 71 male speed sensor supplied in the kit This will leave you with 3 wires for both to reconnect to the new speed sensor After trimming the plastic protective cover from both the chasses wires and the new sensor slide heat shrink wraps over each wire cut to proper length NOTE the heat shrink wrap is not supplied in this kit You will need to source this from an auto parts or electronic retailer The Orange wire is the 5V power supply the Black wire is the sensor ground wire and the White or Brown wire is the sensor speed signal wire The supplied connectors should match factory wire colors to help speed installation With all wires properly connected heat solder only slide shrink tube over soldered wires and heat to seal For added protection the use of 3M electrical tape is recommended over the shrink wrapped wires If desired the use of connectors can be used to allow the disconnection of the sensor without removal It is recommended that quality connectors be used to avoid corrosion at terminal connectors 1998 and older factory connector female Brown or White Black Cut wires ole J k here 5 Orange st SV supply 2 Ground Blac
12. onnector all together Wire color codes and instructions are included later in the instructions 3 This kit will not work on 2007 and newer JK s 4 This kit will not work on TJ Rubicon s or Rubicon Unlimited 5 Proper calibration of speedometer may be needed after installation See chart supplied with instructions for further information The purpose of this kit is to replace the slip yoke portion of the NP231 with a fixed yoke CV style drive shaft assembly A CV equipped drive shaft will be required with this conversion kit The stock drive shaft can be modified to work Proper length and balance are critical High quality drive shafts in the required lengths and configurations are available to compliment this kit for many applications The easiest way to install this kit is to remove the transfer case from your Jeep Removal is not necessary but usually is much quicker and easier and highly recommended The installation of this kit requires almost total disassembly of your transfer case At the end of the instruction packet you will find a complete listing of replacement parts available from OMIX ADA for your NP231J transfer case All parts are available through the retailer this kit was purchased from Pg 1 Rugged ir Ridge Installation Instructions 18676 72 Several suggestions that may help 1 The installation of this kit requires you to nearly disassemble the entire case If you need to rebuild or feel like you have add
13. ont case half planetary assembly Place the front output shaft on the chain and work them into position with the main shaft and case Once they are properly located replace the mode spring onto the shift rail Tall edge towards transfer case Tone Ring Short edge and Flange are to point towards the back of the f transfer case and yoke Photo 4 NP231 after completion of the first 10 steps The rear case half is now ready to be installed STEP 11 Clean both halves of the transfer case and remove any excess transmission fluid It is important to not have oil grease or ATF on the case mating surfaces when silicone is used STEP 12 Be sure the oil pump and pick up tube are properly located Use RTV sealant OEM P N 82300234 on the case halves A good seal will prevent oil leaks Slide the rear case half on and into position Do not force the case together Rotate the oil pump as needed to engage the splines The mode fork shift rail needs to extend through the rear case half Before installing the case bolts start one to hold the back half of the case in place and inspect to see 1f oil pump pickup tube is still in the correct location If yes than install all the bolts in their proper locations and torque to 25 30 ft Ibs Reinstall the selector lever STEP 13 With the back half of the case tightened to the proper torque spec slide the speed sensor tone ring onto the main shaft see image above
14. r with prior approval from the Company Return Authorization Number is required freight pre paid to the Company address listed below This warranty does not apply to any product or part thereof which in the opinion of the Company has suffered or been damaged through alteration improper installation mishandling misuse neglect accident or by acts of nature THE EXTENT OF THE COMPANY S LIABILITY UNDER THIS WARRANTY IS LIMITED TO THE REPAIR OR REPLACEMENT PROVIDED ABOVE AND IN NO EVENT SHALL THE COMPANY S LIABILITY EXCEED THE PURCHASE PRICE PAID BY PURCHASER FOR THE PRODUCT This Warranty is in lieu of all express warranties or liabilities ANY IMPLIED WARRANTIES INCLUDING ANY IMPLIED WARRANTY OF MERHCHANTABILITY SHALL BE LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY ANY ACTION FOR BREACH OF ANY WARRANTY HEREUNDER INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY MUST BE BROUGHT WITHIN THE PERIOD OF 90 DAYS FROM DATE OF ORIGINAL PURCHASE IN NO CASE SHALL THE COMPANY BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL DAMAGES FOR BREACH OF THIS OR ANY OTHER WARRANTY EXPRESS OR IMPLIED WHATSOEVER No person or representative is authorized to assume for the Company any liability other than expressed herein in connection with the sale of this product Some States do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damage so the above limitations may not apply to you Thi
15. s warranty gives you specific legal rights and you may also have other rights which vary from state to state Omix ada Inc 460 Horizon Dr Suite 400 Suwanee Georgia 30024 Rugged iV Ridge
16. the vehicle Be sure to reinstall the drain plug and fill it to the recommended level with the proper fluid Reconnect all the required items like the front drive shaft shift linkages new 3 wire connector into factory harness NOTE 4 new 5 15 12 point bolts have been supplied to aid with the installation of the rear drive shaft to output yoke Do to clearance a standard 2 wrench can not be used for this application IMPORTANT INFORMATION STEP 18 Proper rear CV drive shaft measurements Take measurements for the required CV equipped rear drive shaft You will need to replace your rear drive shaft with a new unit as the original slip yoke shaft can no longer be used Measure a straight line from the transfer case rear output yoke to the rear pinion yoke to determine the required length of your new driveshaft If a new drive shaft is needed OMIX ADA Rugged Ridge does have shafts that can be purchased depending on your vehicles overall lift These shafts are for general use and you may want to have a custom unit made if the sizes offered will not work for your application Transfer Case Output Rear Diff Yoke Measure 6 Rugged Ridge Installation Instructions 18676 72 Drive shaft modifications to Original Unit The modification of your drive shaft should be performed by a local driveline repair shop that is capable of balancing your finished assembly Note Use a C V joint amp a long slip spline style
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