Gear Train Sound When Manual Transmission Is In Neutral – 2000-2001 Jeep Wrangler

NUMBER: 21-002-01
GROUP: Transmission
DATE: Feb. 02, 2001

 

SUBJECT:

Gear Train Sound When Manual Transmission Is In Neutral

 

OVERVIEW:

This bulletin involves the replacement of the transfer case range lever torque shaft.

 

MODELS:

2000 – 2001

(TJ)

Wrangler

 

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A NV3550 MANUAL TRANSMISSION AND BUILT PRIOR NOVEMBER 18, 2000 (MDH 1118XX).

 

SYMPTOM/CONDITION:

The customer may experience a transmission gear train sound when the engine is at idle and the transmission is in neutral with the clutch released. The sound may be described as a light gear rattle or gear growl. The gear train sound may appear to be coming from the transmission shifter and/or center console area. The sound may be more noticeable in higher ambient temperatures or as the transmission reaches its operating temperature. The gear train sound enters the passenger compartment by way of the transfer case range lever linkage. A revised torque shaft has been released to improve the isolation of the gear train sound.

 

DIAGNOSIS PROCEDURES:

If the customer experiences the above condition, then perform the Repair Procedure.

 

PARTS REQUIRED:

Qty.	Part No.	Description
1	52078872AC	Shaft, Transfer Case Torque
1	04318063	Grease, Multi-Purpose

 

REPAIR PROCEDURE:

1. Shift the transfer case range lever into the 4L (low) position.
2. Fold the carpet, that is in front of the driver’s seat, back towards the center console.
3. Remove the four (4) bolts used to retain the transfer case frame bracket to the vehicle body. The bolts are located on the driver’s side of the transmission tunnel. If necessary, refer to the appropriate Wrangler Service Manual, Group 21 – Transmissions and Transfer Cases for any additional technical assistance.
4. Raise and support the vehicle.
5. Remove the transfer case torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket.
6. Remove the ends of the shift rod and the torque shaft rod from the torque shaft.
7. Liberally lubricate the frame bracket bushing with multipurpose grease, p/n 04318063 or equivalent. Lubricate both ends of the new torque shaft, p/n 52078872AC.
8. Assemble the frame bracket, bushing, and rubber boot to the torque shaft.
9. Install the torque shaft assembly to the transmission bracket bushing.
10. Lower the vehicle.
11. Attach the frame bracket to the vehicle body with the four (4) bolts.Tighten the bolts to 5.1 Nm (45 in. ).
12. Verify that the transfer case range lever is fully seated in the 4L position.
13. Raise and support the vehicle.
14. Install the end of the torque shaft rod to the new torque shaft.
15. Loosen the lock nut on the shift rod trunnion so that the trunnion will slide easily on the shift rod.
16. Connect the end of the shift rod to the new torque shaft.
17. With the range lever in 4L, tighten the trunnion lock bolt.
18. Lower the vehicle and verify transfer case shift operation

 

POLICY:

Reimbursable within the provisions of the warranty.

 

TIME ALLOWANCE:

Labor Operation No:
21-03-07-90	Shaft, Transfer Case Torque – Replace	0.5 Hrs.

 

FAILURE CODE:

P8

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