Type 231 transfer case, cracked pretty much destroyed. Found a new one or slightly used one, the old is still in. I nedd to know how to remove the old and then install the (new) one. It's an 87 wrangler 6 cyl standard trany.
You need to remove the skid plate/crossmember (6 3/4 bolts at the frame and 3 nuts at the trans mount.). Support the trans first with a jack and a block of wood before removing. Remove the rear drive shaft from the differential and pull it out of the transfer case. Unbolt the front shaft from the transfer case only and wire to the side with a coat hanger.Disconnect the vacuum connector from the top and the speedo cable. Unbolt the shifter and bracket (tricky operation). unbolt the transfer case from the trans and pry it rearward with a floor jack under it. Reverse operation to install. The 87 used a different case than the 231 from the factory but the 231 will work. You may have a concern with the length of the shift linkage. If you do anyone with a welder can extend it for you. Good luck hope this helps.
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The pilot bearing is pressed into the flywheel and you need a pilot bearing/bushing puller. Some A/P stores will rent it to you for free (deposit). the throwout bearing is held onto the clutch fork normally by clips. Sometimes you have to take the "fork" out to get the bearing off.
Make sure to note how "deep' the pilot bearing/bushing is so that when you install the new one it is set at the right depth.
This is pretty straight forward once you have a few basic tools. You will need a suction pump and a bowl/bucket type container to put the old fluids into.
Both the front and rear diffs should have a rubber inspection plug you can remove to pump the old stuff out, and the new gear oil in.
Synthetic fluids last longer and work better.
The transfer case should have two threaded allen plugs (or similar) that are removed to drain and then refill the T case. Remove bottom then top to drain. Reinstall bottom then refill.Then reinstall top.
Need replace it; the switch is on the Transfer Case.
In order to get the correct switch you need to determine what type
of transfer case you have. You can do this by crawling under the
vehicle near the middle and look for a small round metal tag mounted on
the back side of the transfer case. Once you have that number (new
process type 231, 242, 249...). If your
local jeep dealer is of a friendly sort you may even be able to avoid
all the crawling around and just tell the parts manager your VIN# and he
will be able to tell you what type transfer case you have - provided
that it is the factory installed original.
Loosen the wheel hub nut. Remove the front road wheel and tire. Remove the tie rod end retaining nut. Using the special tool 204-192 Ball joint Splitter detach the tie rod end. Remove the subframe reinforcement plate retaining bolts. Loosen the subframe rear mount bolt. Loosen the subframe front mount bolt. Remove and discard the wheel hub nut. using spcial tools 204-269Forcing Screw,205-491-01 adapter nuts,205-491 wheel hub puller Detach the wheel knuckle. Remove the lower arm ball joint retaining bolt. Reposition the lower arm. Detach the wheel knuckle. using special tools 307-443 RH Halfshaft splitter ,307-442 RH Halfshaft splitter handle detach the halfshaft. Remove the exhaust muffler inlet pipe. Remove the halfshaft seal. Remove the transfer case Y bracket retaining bolt. To prevent damage to the transfer box internal seal, make sure that the link shaft is not retracted further than 200 mm from the transfer box casing. remove the halfshaft. Attach special tools to the halfshaft. Lever the special tools to displace the halfshaft. Install the transfer case Y bracket retaining bolt. Remove the halfshaft. Use suitable protective covers to protect the barshaft. Remove the halfshaft snap ring. Install a new snap ring to the halfshaft. Install a new halfshaft seal. Remove the special tool. Remove the transfer case Y bracket retaining bolt. Remove the special tool. Make sure the CV joint splines are located fully. Do not use excessive force when engaging the CV joint into the link shaft. Install the halfshaft. Install the transfer case Y bracket retaining bolt. Tighten to 25 Nm. Attach the wheel knuckle. Reposition the lower arm. Attach the wheel knuckle. Install the lower arm ball joint retaining bolt. Tighten to 83 Nm. Install the exhaust muffler inlet pipe. Tighten the subframe front mount retaining bolt. Tighten to 142 Nm. Loosely install the subframe rear mount retaining bolt. Install the subframe reinforcement plate retaining bolts. Tighten to 35 Nm. Tighten to 142 Nm. Install the tie rod end. Tighten to 35 Nm. Loosely install a new wheel hub nut. Install the front road wheel and tire. Tighten the wheel hub nut. Tighten to 330 Nm. Check the subframe alignment.
It's probably the chain in the transfer case. I had mine replaced at 150,000 miles and it cost $1500.00 to do a full rebuild. And that included them removing and installing the transfer case and a new yoke for the driveshaft.( Because the play in the transfer case grooved the old one.)
I just fixed the same problem with my own GC Limited - and it WAS a
dealer part (in my case). In order to get the correct switch you need
to determine what type of transfer case you have. You can do this by
crawling under the vehicle near the middle and look for a small round
metal tag mounted on the back side of the transfer case. Once you have
that number (new process type 231, 242, 249...) you can order the
If your local jeep dealer is of a friendly sort you may
even be able to avoid all the crawling around and just tell the parts
manager your VIN# and he will be able to tell you what type transfer
case you have - provided that it is the factory installed original.
According to the mechanic who works on my 93 Jeep it's one of three
things: 1) Corrosion on the connector to the switch (which is located on
top of the transfer case). 2) A bad switch. Part cost about $22.00, or 3) A bad console display. he says they have had a fair number of console
display units fail. That one runs about $240.
My Jeep display it only once in a while. I have checked the
connections and they are fine so the switch replacement is next. If that
doesn't fix it I will opt to ignore the error.
Hope this helped (remember comment and rated this).
Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair
Transfer Case Assembly -REMOVAL & INSTALLATION
Models Even the 2WD Samurai uses a transfer case. Rather than use a straight
line driveshaft from the transmission to the differential, the Samurai
leaves the transfer case in place and replaces its internal working with
a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts
used in the 4WD vehicle.
On 4WD vehicles, remove the transfer case shift lever.
Raise and support the vehicle safely.
Drain the oil from the transfer case.
Matchmark and remove the driveshafts from the transfer case
assembly. Not all of the driveshafts need to be completely removed from
the vehicle, just unbolted from the case flanges. In most cases, the
shaft or shafts on one side of the transfer case can be repositioned and
supported out of the way.
Support the transfer case using a suitable transmission jack.
Disconnect the speedometer cable from the transfer case.
On 4WD vehicles, disconnect the 4WD switch lead wire at the
Remove the three mounting bolts and/or nuts securing the transfer
case to the chassis, as applicable.
Carefully lower the transfer case from the vehicle.
Position and install the transfer case. Tighten the mounting bolts
to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft.
lbs. (25-34 Nm).
On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
Connect the speedometer cable to the transfer case.
Properly refill the transfer case with an approved type of gear
Align and install the driveshafts to the transfer case.
On 4WD vehicles, install the transfer case shift lever.
Remove the jackstands and carefully lower the vehicle.
Sidekick, Tracker, Sidekick Sport and X-90 Models On
these models the transfer case is bolted to the transmission and takes
the place of the 2WD transmission's extension housing. Therefore,
transfer case is removed or installed as part of the transmission