TSB# 21-003-04 NV-241 Leak??????

[anchovy]

Anybody know the details of this TSB? Trying to figure out what they change. This thing won't stop leaking out of the output shaft. I've tried diffirent seals, diffirent yolks, shaft isn't bent, vent isn't clogged....

It's in an 04 rubi with a RE 4.5 lift, and tom woods shaft.

[Bryan C.]

21-003-04
GROUP: Transmission
DATE: March 09, 2004

SUBJECT:
NV-241 Transfer Case Fluid Seepage From Area Of Rear Output Shaft Retainer
OVERVIEW:
This bulletin involves the replacement of the NV-241 transfer case rear output
shaft retainer/extension housing and related seals.
MODELS:
2003 - 2004 (TJ) Wrangler
NOTE: This bulletin applies to Rubicon vehicles equipped with a NV-241 transfer
case (sales code DHW) and built prior to March 01, 2004 (MDH 0201XX).
SYMPTOM/CONDITION:
The customer may notice fluid seepage (ATF+4) coming from the NV-241 transfer
case. Upon closer inspection the fluid seepage may be coming from the rear output
shaft retainer/extension area. The cause of the seepage may be the interface
between the rear output shaft seal to the rear retainer/extension.
DIAGNOSIS:
If fluid seepage is present between the rear output shaft seal and the rear
retainer perform the Repair Procedure.
PARTS REQUIRED:
Qty. Part No. Description
1 05093606AA Retainer, t/case rear (includes rear
output shaft seal)
1 04210973 Washer, t/case rear output shaft sealing
1 05093612AA Seal, vehicle speed sensor
1 04167924 Nut, t/case rear flange
AR (1) 05093605AA Sleeve, rear flange wear (seal slinger)
1 04883971 RTV, Engine Sealant
3 05013457AA Fluid, transmission/transfer case (ATF+4)
21-003-04 -2-
SPECIAL TOOLS/EQUIPMENT REQUIRED:
6719A Holder, Flange
8992 Puller, Flange
REPAIR PROCEDURE:
NOTE: Prior to dissassembly, both the rear propshaft-to-rear companion
flange connection and the rear companion flange-to-rear output shaft
connection must be marked (indexed) for assembly reference to prevent
possible driveline vibration after assembly.
1. Partially raise and support the vehicle.
2. Shift the transfer case to its Neutral position. Raise vehicle.
3. Remove the skid plate.
4. Support the transmission.
5. Remove the crossmember supporting the transfer case.
6. Drain the tranfer case fluid. Install drain plug.
7. Mark (index) the rear propshaft to the transfer case rear flange for assembly reference.
8. Disconnect the rear propshaft from the transfer case rear flange. Move the
propshaft out of the way and support properly.
9. Using special tool - Holder 6719, remove the rear companion flange nut.
10. Remove the rubber sealing washer.
11. Mark the transfer case rear companion flange-to-rear output shaft
connection for assembly reference.
12. Remove the rear companion flange from the output shaft.
NOTE: The companion flange is a taper fit onto the output shaft. It may be
necessary to use Puller 8992 to remove the companion flange.
13. Remove the vehicle speed sensor bolt.
14. Remove the vehicle speed sensor from the retainer/extension housing.
15. Remove the rear retainer/extension housing. Tap the retainer/extension housing
once or twice with a plastic mallet to break the sealer bead.
16. Carefully remove the speed sensor tone wheel and metal indexing (dowel) pin.
17. Clean the mating surface of the transfer case housing of old sealer and oil
residue. Clean the retainer/extension housing mating surface.
18. Apply a bead of RTV to the mating surface of the rear case. Keep sealer bead
width to a maximum of 3/16 inch. Do not use an excessive amount of sealer
as excess will be displaced into the case interior.
19. Rotate the output shaft so that the hole in the output shaft for the speed sensor tone
wheel metal index pin is facing up (12 o’clock position). This will prevent the index pin
from falling out during installation of the tone wheel and rear companion flange.
20. To hold the index pin in place, apply a small amount of grease to the pin. Install
the tone wheel index pin to the output shaft hole.
21. Install the speed sensor tone wheel. Verify that the pin is in the 12 o’clock position.
Verify that the tone wheel covers the index pin and is fully seated to the output shaft.
-3- 21-003-04
22. Without rotating the rear output shaft, install the rear retainer/extension
housing to the transfer case. Apply RTV to the attaching bolts. Tighten
the attaching bolts to 16-25 Nm (12-18 ft. lbs.).
23. Clean the wear sleeve (seal slinger) on the rear companion flange. The wear
sleeve surface must not be scratched. Replace the wear sleeve if cleaning is not
possible. To remove the wear sleeve use a suitable cold chisel to strike the slinger
hub parallel to the centerline in several places to expand the wear sleeve. A new
sleeve can be driven onto the flange hub using a suitable pipe tool.
24. Install a new seal to the vehicle speed sensor.
25. Install the vehicle speed sensor to the retainer/extension housing. Tighten
the attaching bolts to 11-16 Nm (8-12 ft. lbs.).
26. Install the output shaft sealing washer. Verify that the sealing washer is fully seated
against the output shaft face prior to installing the rear companion flange.
27. Note the index marks made earlier on the output shaft and rear companion flange.
The mark on the shaft may need to be transferred to the sealing washer.
28. Make sure the speed sensor tone wheel is fully seated.
29. Align the rear companion flange and output shaft index marks and install
the rear companion flange to the output shaft.
30. Hand install the rear companion flange nut.
31. Using Holder 6719, tighten the rear companion flange nut to 122-176 Nm (90-130 ft. lbs.).
32. Align the propshaft index mark to the rear companion flange. Install the propshaft
to flange attaching bolts. Tighten attaching bolts to 115 Nm (85 ft. lbs.).
33. Fill the transfer case with fluid.
34. Install crossmember.
35. Lower vehicle
36. Shift transfer case into 4HI position.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation
No:
Description Amount
21-03-23-91 NV-241 Transfer Case Fluid Seepage 1.0 Hrs.
FAILURE CODE:
65 Leaks