Bang Crunch

[ren0vator]

Originally Posted by Clarky

If Murchison don't have them you have the option of paying through Amazon which offer DHL Express shipping all for $735au delivered. Only $40 more then the Aussie list price, or $765.50 with UPS express.

The Pellicano family will be richer to the tune of $1.8 million in annual rent.
They own a 24,387 square metre distribution centre in the Dandenong, Vic.
I found out on Sunday that Amazon has agreed to lease the place to begin its Australian operation.

[ren0vator]

Pictorial strip down
OEM Manual is accurate



32mm single hex


Sump Magnet in rear case under oil pickup


Internal Pump


Box set in neutral
Mark shift fork and sector gear


Support Shift Shaft


Shift Rail


A Magnet is the easiest way to remove pump gear


Rear Output Shaft snap ring
Then remove centre casing


Clutch Pack snap ring


Clutch Pack


Front Output Shaft snap ring (inner)


Drive Chain


Front Output Shaft snap ring (outer)


Front Output Shaft
Here's my leak
Note this seal has a metal casing which protects the shafts from damage


Input Shaft snap ring is behind the input shaft seal


Easiest way to remove seals from the casings
Punch opposite sides with chisel or screwdriver and lever out


That's a one beer job

[ren0vator]

Stripped the transmission down today
And I'd just like to say;
I still don't get steel bolts in alloy housings


Noted some aberration with K2 apply slide and B2 release snap ring shroud
(they are my explanations not official Jeep terms)
But it all looks as as a transmission with 150kms should
Stuffed if I know

That's a two beer job (with the right tools)

It's not a difficult strip down but it does require specialist tools
e.g. Like a Beliville return spring compressor


Onward and upward ...

[ren0vator]

NAG1 = W5A580
but in the diesel's case it is a W5J400
They all have the same internals but different torque converters
My diesel has a larger pilot and reverse mounting to V8's and V6
If you require any parts for these units, head straight to America
NIL stock Australia

The diesel's valve body is a 722.600
Even though this number is the same
as Mercedes and Jaguar,
they are NOT the same valving
Go figure

[ren0vator]

The automatic transmission service manuals I've been using
Shared via Google Drive

[ren0vator]

Seal Kit turned up so spent the day re-assembling the transfer case

First job drive the inner seal casings of the shafts.
Nothing to fancy, just keep the punch away from the shaft surface
Drive both sides off in an even manner


Inner seal won't be used again


Install the new inner seals onto the shafts with 60mm ID pipe


Just like a bought one


Install the outer seal into the case with a hammer
If you're not confident, or a bad shot, utilise a seal intaller


Here's the clutch pack inside the NV245
These are the same friction material inside an automatic
Don't look like they need synthetic to me


However ...
They are single sided friction plates and the first one spins against the compression disc.
You can see there is a bit of wear here.
So there's a strong case for a friction additive, or synthetic oil


Brand new chain has 2mm less movement than the OEM with 150km's
Hardly worth the effort


The manual says to simply install the shift fork onto the shift hub

You Tube

Took me a while to figure out
I installed the shift fork pivot shaft and shift fork into the centre case


and cable tied the damn thing into place
This enabled me to eliminate using the little people from the garden inside the box


The machined surfaces need very little sealant
Even a 2mm bead like this



Still oozes out the sides



Final seal deep inside the rear output shaft


That was a three beer job

[ren0vator]

Just a quick note to let you all know
I've finally got the transmission issue sorted
Turned out to be the Torque Converter Clutch
Someone's buying way too much bauxite at the moment
Got next week off so I'll post some pics then

Cheers All