Advance Adapters 50-6804 - Manual (Page 2)

ADVANCE ADAPTERS INC. P/N: 50-6804
P.O. Box 247, 4320 Aerotech Center Way New Item: (10/04)
Paso Robles, CA 93447 PAGE 2 OF 3
Telephone: (800) 350-2223 Fax: (805) 238-4201 Page Rev. Date: 06-01-04
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 recommend that you contact our sales department for more information. This instruction sheet is only to be used for the assembly of Advance Adapter
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.
GM 4WD TH350 AUTO TO JEEP NP231
TRANSFER CASE (27-SPLINES) UP TO 1995
Remove the front yoke nut with a 1-1/8" socket using an impact wrench. Remove the rear case bolts.
A 10mm 12 pt. socket is needed for the spline head bolt and a 15mm socket for the remaining bolts.
NOTE: The two black oxide finished bolts are located at the case dowel positions and require a washer
under them. Start to remove the rear case from the front case by inserting pry bars at the cast-in
locations
ONLY! Pry apart evenly to break the sealer bead along the case mating surfaces. The front
output shaft and chain should be retained with the rear portion of the case.
On the front side of the transfer case, you'll need to remove
the 4 bolts that retain the aluminum bearing retainer. Once this
is removed, you'll find a snap ring that retains the input gear
to the cases' input bearing. This snap ring must be removed
so that the input gear can be removed from the inside.
Jeep Wranglers 1987-96 will require shifter bracket P/N 715523, Some applications will the purchase of a stock Jeep
bracket, AA P/N 715545. This is the most universal for YJ Wranglers. TJ conversions will need bracket P/N 715542
to locate the complete linkage to the transmission and transfer case assembly.
THINGS TO CONSIDER BEFORE YOU BEGIN:
1. Medium strength thread locker is recommended on all threaded fasteners.
2. A sealant such as RTV (like the OEM sealant) is needed and is available from your local Jeep/Dodge dealer.
P/N 82300234.
INSTRUCTIONS:
This new input gear will only fit the NP231 transfer cases. The installation of the gear will require the complete
disassembly of your NP231 transfer case. Since the transfer case has to be completely disassembled, this is also a
good time to install a short output shaft kit (fixed yoke kit) if you have not done so already.
If you've never disassembled a New Process transfer case, here are a couple of points to keep in mind that will make
the installation much easier:
1. Keep all bolts, nuts, washers, etc. separated into groups as you remove them. Make sure you keep them in a 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 have a clean, spacious area to perform the installation.