Installation Instructions for RR231
Contents
1. 388 0816 yBsSUSPENSIO Part RR231 NS 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 yoke with ATF c A little 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 Be sure to apply thread lock to the retaining nut Torque to 140 150 ft lbs with 1 1 8 socket d Install your stock speedometer housing into your new tailhousing A touch of RTV Blue silicon around the o ring will help seal this area 12 Fill to recommended 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 mod ifications 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 SKYJACKERfi components We recommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other related equipment These2. Technical Support 318 388 0816 FIXED YOKE KIT Fig 10A Bearing Installed and Retained with the 716464 Fig 11A Seal 10 Short Tailhousing Installation a Prelube bearing amp seal in new short tailhousing assembly Fig 11A case thin film c While supporting main shaft slide new tail assembly into position 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 b Apply sealant to tailhousing mating surface of rear d 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores Part RR231 Page 11of 11 Technical Support 318
3. manuals are normally available at automotive dealerships and parts stores YJACK Zs SUSPENSIONS ANY Part RR231 BULLETIN Technical Support 318 388 0816 ATTENTION NOTE lf your jeep transfer case out put shaft is equipped with a harmonic balancer this balancer must be removed with a puller at step 5 dur ing disassembly The harmonic balancer is pressed onto the output shaft a balancer puller will be required to remove this item without damage The balancer has three threaded holes to aid in this disassembly see arrow at right Refer to repair manual during this process This balancer will not be required once the fixed yoke kit is installed YJACK Zs SUSPENSIONS RNG Part RR231 BULLETIN Technical Support 318 388 0816 ATTENTION NOTE lf your jeep transfer case out put shaft is equipped with a harmonic balancer this balancer must be removed with a puller at step 5 dur ing disassembly The harmonic balancer is pressed onto the output shaft a balancer puller will be required to remove this item without damage The balancer has three threaded holes to aid in this disassembly see arrow at right Refer to repair manual during this process This balancer will not be required once the fixed yoke kit is installed
4. of the drive gear to make sure it is a Clean all components free of any type of debris b Prelube all components with a quality assembly lubricant Fig 3A c Slide drive sprocket into position d Slide mode hub into 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores Technical Support 318 388 0816 ysSUSPENSIO Part RR231 NSRS NP231 SHORT SHAFT FIXED YOKE KIT Shafts that resemble the YJ ASSEMBLY CONSIDERATIONS Fig 3A New Main Output Shaft Assembly Main shaft assembly a Clean all components Prelube all components with a quality assembly 1 Component assembly A a Ca
5. Part RR231 Page 1 of 11 S Ze SUSPENSIONS AN Technical Support 318 388 0816 NP231 SHORT SHAFT FIXED YOKE KIT KIT CONSISTS OF No Qty Part No Description 1 51 7905 TAILHOUSING DIECAST 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 300627 SNAP RING SPEED O RING GEAR 1 716318 BEARING 207 OPEN BALL No Snap Ring 1 716464 SNAP RING 207 BEARING 1 716465 RETAINER RING MODE 1 716751 SEAL TAILHOUSING WON OI ON SPECIAL NOTE On vehicles that have the vacuum actuator on the tailhousing we have supplied a tail housing that will provide you the necessary vacuum actuator connection NOTE The shift rail must be shortened to protrude 1 when in 4WD low or 4WD high INSTALLATION PROCEDURES 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 at our technical assistance line at 318 388 0816 Monday through Friday 8 00 AM to 6 00 PM CST 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 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 are a couple of points to keep in mind th
6. at will make the installation much easier if you ve never disassem bled a New Process transfer case 1 Keep all bolts nuts washers etc separated into groups as you remove them Make sure you keep them ina labeled container that indicates what part of the transfer case they came from 2 Keep all small parts in separate containers and label as to location and origin 3 Make sure you have plenty of time and a clean spacious area to perform the installation THINGS TO CONSIDER BEFORE YOU BEGIN 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 threadlocker 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 con versions 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 recom mend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi 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 normal
7. ate chain amp shaft with ATF b Insert main shaft assembly into the housed planetary assembly 5 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 With all components 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 Part RR231 Page 9 of 11 Technical Support 318 388 0816 FIXED YOKE Fig 7A Thin film RTV Applied Prior to Mating Case Halves Fig 8A Case Halves Assembled 7 Assembly of case halves Fig 8A a Slide the pump amp case into position b If you have difficulty check for possible problems DO NOT FORCE Mode fork rail extends through rear case c Install all fasteners in their original positions Black bolts at dowel locations d Torque evenly to 27 34 N m 20 25 ft lbs 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 p
8. d b Remove clean and inspect the inner case for wear 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKEfi components We recom 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 Technical Support 318 388 0816 Part RR231 NS yBsSUSPENSIO NP231 SHORT SHAFT FIXED YOKE KIT SKYJACKERfi has supplied two types of NP231 output shafts over the past years The current production output shaft is similar to the NP231 shaft found in the TJ series Wranglers This TJ shaft did not use a caged needle bearing on the drive sprocket We decided to use this design since this is the most current design engineered amp being produced by New Process Gear The earlier short shaft we supplied was similar to the YJ series Wranglers This shaft uses a set of caged roller bearings installed in the d
9. ents 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 avail able at automotive dealerships and parts stores Technical Support 318 388 0816 ZS SUSPENSIO Part RR231 NSRS NP231 SHORT SHAFT FIXED YOKE KIT Fig 1 Yoke Nut Removal Fig 3 Slinger Removed TJ Illustrated 1 Remove Speed o drive Remove output shaft boot Spread band clamps ti Remove front yoke nut with an Awl Slide boot off a Move range lever to 4L position Remove slinger this one is tough Good thing you a Remove front yoke nut with 1 1 8 socket using won t need this later Fig 3 an impact wrench Fig 1 Remove stop spacer amp snap ring Fig 4 3 Remove yoke Note If difficult use a uller Discard seal washer 4 Remove selector lever Fig 2 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained fo
10. ly available at automotive dealerships and parts stores Part RR231 Page 2 of 11 QR VACKE Technical Support 318 388 0816 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 T C OUTPUT MEASURE Fig A DIFFERENTIAL YOKE 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 disassem bly procedures Step 1 Fig 1 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 recom mend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi compon
11. p Shaft Removal 11 Disconnect the pump pickup tube visible at lowest point of 14 Front output shaft removal tailhousing opening Fig 9 a Pull the front output shaft out of the front a Remove the pump from the main output shaft bearing Fig 11 b Inspect the pickup tube o ring in the pump and b Slide drive chain off the rear output shaft and replace if needed The same goes for the front shaft remove both shaft and chain for cleaning amp seal in the pump DO NOT disassemble the pump it inspection is not a serviceable item 15 Rear output shaft removal a Grasp the main shaft Remove the rear case bolts A 10mm 12 pt socket is and remove the shaft drive sprocket and mode hub needed for the spline head bolt amp a 15mm socket for assembly the remaining bolts NOTE The two black oxide finished bolts are located at the case dowel positions and require a washer under them Fig 12 Front Drive Chain amp Shaft Removal 16 Output shaft disassembly Fig 10 Rear Case Half Removal re Homove the mode hub retaining ring with heavy l duty snap ring pliers Fig 12 13 Remove the rear case from the front case by inserting pry b Slide remaining components mode hub amp drive bars at the cast in locations ONLY Fig 10 sprocket off shaft a Pry apart evenly to break the sealer bead along the 17 This is as far into the case you need to go unless case mating surfaces you find foreign material inside usually cause
12. r specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores Part RR231 Page 4 of 11 QE VACKE Technical Support 318 388 0816 NP231 SHORT SHAFT FIXED YOKE KIT Fig 5 Rear Seal Removal 8 Remove rear seal Collapse with punch 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 10 Remove tailhousing bolts with 10mm socket amp Fig 7 remove tailhousing Fig 8 SPECIAL NOTE The components packaged in this kit have been assembled and machined for specific type of con versions Modifications to any of the components will void ally passive warranty or return privileges If you do not fully understand modifications or changes that will be required to complete your conversion we strongly recom mend that you contact our sales department for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi 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 Technical Support 318 388 0816 Part RR231 NS ys SUSPENSIO NP231 SHORT SHAFT FIXED YOKE KIT Fig 9 Oil Pump Removal Fig 11 Front Drive Chain am
13. re should be taken not to distort the housed lubricant Fig 3A bearing element when installing the new e a eres ed o bearing Fig 1A 7 b Press bearings into both sides of the drive Hubs Fig Ay ring into position after the mode sprocket so they seat just past the inside i x chamber Fig 2A c If you are not comfortable at this point you should take this step to a local machine shop Fig 1A Drive Sprocket Needle Bearing Installation 2 a Fig 2A Installed Needle Bearings in Drive Sprocket Fig 4A Large Retaining Ring Installation CONTINUE TO PAGE 9 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores KYJACKE sUSPENSION NP231 SHORT SHAFT Fig 5A New Main Output Shaft Assembly 3 5 6 Output shaft and drive chain assembly a Lubric
14. rive sprocket This information is provided to you to verify which style shaft you have so installation is properly performed TJ style shaft YJ style shaft Current kit design f Previous kit design No needle bearings required Needle bearings P N 716319 amp See Page 7 for assembly consid thrust washer P N 716320 required erations See Page 8 for assembly considerations 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 modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores Technical Support 318 388 0816 Part RR231 NSN yBsSUSPENSIO NP231 SHORT SHAFT FIXED YOKE KIT Shafts that resemble the T if ASSEMBLY CONSIDERATIONS Fig 1A Drive Sprocket Needle Bearings Fig 3A New Main Output Shaft Assembly These bearings must be removed Once the bearings are 2 Main shaft assembly removed clean the inside
15. rivileges If you do not fully understand modi fications or changes that will be required to complete your conversion we strongly recommend that you contact our sales depart ment for more information This instruction sheet is only to be used for the assembly of SKYJACKERfi components We rec ommend that a service manual pertaining to your vehicle be obtained for specific torque values wiring diagrams and other relat ed equipment These manuals are normally available at automotive dealerships and parts stores YACKE Zs5USPENSIONS NP231 SHORT SHAFT Fig 9A Speed o Ring Gear Install 8 Assemble speed o drive a Install retaining ring located just behind the pump b Slide ring gear into position c Install retaining ring behind ring gear Fig 9A 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 new tailhousing has a pocket depth of 1 125 Shift your transfer case so the shift rod is protruding the fur thest 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 fll this rail to be shortened measure 1 5 photo above e Using a hack saw or cutoff wheel and safety glasses trim the shift rail shaft so that it protrudes only 1 photo above right Part RR231 Page 10 of 11
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