Atlas Transfer Case - ZJ Cherokee
On all of these late model Jeeps (if retaining your stock transmission), Chrysler used an oil weep hole on the stock adapter housing. This weep hole was located in one of two locations: on the adapter surface where the transfer case mates to the adapter, or on the bottom center of the casting near the crossmember foot. These weep holes were designed for the purpose of informing you when the seal in the tailhousing would fail. The Atlas does not always have the same input shaft length as your stock New Process transfer case to make contact to this seal and the Atlas is double sealed in the front of the transfer case to prevent any fluid transfer. Therefore; we highly recommend plugging the weep hole using RTV Blue silicone (if on the adapter housing face), or RTV Blue silicone and a sheet metal screw (when located near the crossmember foot). This will prevent any type of fluid leak when installing the new transfer case.
The Atlas is designed with a seal and a sealed bearing on the input shaft. The reason for this is to prevent mixing of dissimilar lubricants. Whether this is a stock transmission adapter or special transfer case adapter, gearbox contamination should not be a concern.
On some stock transmissions, most notably the Peugeot (21 spline), the AW4 (21 spline), and the late model Cherokee 23 spline transmissions A518 (46RH) & A500, you may have a spline engagement problem. If the splines bottom out before the two mating surfaces meet, you may be required to use a spacer adapter. DO NOT force these components together.
All of these vehicles utilized the same type of speedometer housing in the stock New Process transfer case. The Atlas was designed to accept the stock New Process speedometer housing. If your speedometer is correct (with reference to tire size and axle gear ratio) the stock speedometer will not change. If you plan on changing tires or gear ratio, please use the Speedometer Charts located in this manual. The speedometer housing is retained into the Atlas with a metal clip. When the housing is installed into the Atlas tailhousing, the speedometer housing should be rotated clockwise or counterclockwise until the speedo gear meshes with the Atlas output speedometer gear. The new seal kit you received with your Atlas should be installed to prevent any fluid leakage.
Transfer cases like the Rock Trac 241 use a sensor rather than a speedometer housing. The speedometer housing found on the NP231 will generate the same signal as the Rock Trac sensor. If you are replacing a Jeep transfer case that used a sensor and not a speedometer housing, than we can assist you with the correct parts to fit the Atlas transfer case and retain your stock speedometer.
Rotation & Oil
The two stock rotations of the New Process transfer case are 13 or 23 degrees. We recommend the Atlas be installed at either a stock or higher rotation. The recommended 2 quarts (2-speed Atlas) or 2-1/2 quarts (4-speed Atlas) of Atlas oil will be used. As mentioned earlier in this manual, if the Atlas is overfilled it will purge the excess oil out the breather tube. You should also replace the stock breather hose and restrictive vent.