SYE help...

ZachMan said:

Okay replacing my 242 with a 231. I should have my PORC HD SYE on Monday.

Anywyas going from memory (5-6 years ago) I have started to tear down the 231. I am just starting and at this point:

http://i2.photobucket.com/albums/y48/BigNutt/n.jpg

Pulled the rubber boot off the output shaft and the metal cap off the tail cone and now unbolted and loosened the tail cone. When I pull on the tail cone all the internals come with it and it won't slide off, so do I now need to split the case or what? I know I'll eventually need some good snapring plyers too. Just any help on this would be great.

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ZachMan said:

Also do XJ np231 vary for trannys or no? I was looking at the above article and noticed he talks about differences in Wrangler autos and manuals.

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http://www.novak-adapt.com/knowledge/np231.htm said:

The important variations to look for in the 231 transfer case are in the input gear. The 231 comes in 21 spline and 23 spline versions with long, medium (rare) and short variations.

The long shafts protrude 2.1" from the front mounting face of the transfer case. The short version protrudes 1.2". The rare medium shaft protrudes 1.7". You should be careful when swapping any of these gears due to different bearing widths and gear teeth. The following chart shows how to determine which input gear you might have by transmission. It is always recommended to verify first hand if possible.
21 Spline 23 Spline
Short Input AW4 (through 1990)
AX4
AX5
Peugeot BA 10/5 (earlier)

Earlier (pre-'95) AX15
AW4 (post-'90)
Long Input

Later (post-'94) AX15
TF904
TF999
Peugeot BA 10/5 (later)
Medium Input Jeep ZJ's '93 to '95 only

Because of differences in the cut of the gear, as a general rule; one should not interchange pre-'95 gears with post-'94 gears. These years are not hard and fast delineations. If one is not absolutely certain, disassembly and inspection is required.

Note that some transmissions change spline count. The Peugeot BA10/5 had both 21 or 23 splines. The AW4 had 21 splines through 1990. In 1991 (the same year the 4.0 HO was introduced) the AW4 splines increased to 23.

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ZachMan said:

I know that, I am asking any diff in a 99 XJ 231 with 5-speed and aw4?

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