Advance Adapters 50-0435 User Manual

ADVANCE ADAPTERS, INC. P/N: 50-0435

P .O. Box 247, 4320 Aerotech Center W ay New Item: (01/07)
Paso Robles, CA 93447 PAGE: 1 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 03-28-12

GM 4L60E 4WD HEX BOLT PATTERN TO JEEP

NP231 T/C (27-SPLINES) 1995 & NEWER

KIT CONSISTS OF:
No. Qty. Part No. Description

1. 1 51-0405 CASTING

2. 1 51-9111 CASTING

3. 1 716074 RELUCTOR RING

4. 1 716079 PLUG

5. 1 716203 NP231 INPUT SHAFT

6. 1 *716325A NEEDLE BEARING

7. 1 716511 "O"-RING

8. 1 716517 GASKET

9. 1 716757 SEAL

10. 1 716760 NP231 INPUT SEAL

11. 4 720011 10mm X 1.5 NUT

12. 4 720061 10mm-1.5 X 50mm STUD BOLTS

13. 1 300619 SENSOR

* INSTALLED AT ADVANCE ADAPTERS

INSTALLATION INSTRUCTIONS:

This kit is designed to use a stock 4L60E 4x4 hex bolt pattern transmission to a New Process transfer case. If you do not
have the 4x4 version of the 4L60E, you will have to purchase a new GM output shaft.

When installing the new transfer case adapter, make sure that the transfer case input sleeve and the output shaft do not bottom
out. We have found on occasion that a transmission output shaft may be slightly longer than we have allowed for; and when
coupling into the transfer case, we find a small amount of interference. The adapter housing and shaft must be assembled
to the back of the transmission without interference. DO NOT FORCE THE NEW TAILHOUSING ONTO THE

TRANSMISSION. If assistance is needed, please feel free to call us on our toll free number, 1-800 350-2223.

OPTIONAL ITEMS:

It is possible to utilize the stock 700R-4
rubber mount by fabricating a plate to
transfer the bolt pattern from our
casting to your stock mount, if you are
looking for another option we recom­mend our 716055 transmission mount.
This mount is sold separately.

When assembling the adapter housing to the transmission case, we have provided you with a new square type O- ring seal
to prevent fluid leakage. This O-ring seal is a stock GM item.

This adapter can be used on either Jeep Wranglers 1987 & newer or Jeep Cherokees 1984 & newer. The only difference
is the transfer case shifter linkage.

The adapter is 4.10" thick and will provide an overall transmission assembly length of 25-7/8".

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the 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 vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0435

P .O. Box 247, 4320 Aerotech Center W ay New Item: (01/07)
Paso Robles, CA 93447 PAGE: 2 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 01-23-07

GM 4L60E 4WD HEX BOLT PATTERN TO JEEP

NP231 T/C (27-SPLINES) 1995 & NEWER

Jeep Wranglers 1987-96 will require shifter bracket Part No. 715523. Some applications will need to purchase a stock Jeep
bracket, P/N 715545. This is the most universal for YJ Wranglers. TJ conversions will need bracket No.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 already have not done so.

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.

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.

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of the
components will void any possible warranty or return privileges. If you do not fully understand the 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 vales, wiring diagrams and
other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0435

P. O. Box 247, 4320 Aerotech Center Way New Item: (01/07)
Paso Robles, CA 93447 PAGE: 3 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 01-23-07

GM 4L60E 4WD HEX BOLT PATTERN TO JEEP

NP231 T/C (27-SPLINES) 1995 & NEWER

On the inside of the transfer case, you'll now be able to remove the planetary assembly. Set the assembly on a work bench and locate the snap
ring that retains the input gear into the planetary housing. Remove the snap ring and lift the input gear out of the planetary housing.

Once the input gear is removed, you'll find a thrust washer that must be reinstalled onto the
new 27 spline input. When comparing the two input gears, they should look the same except
for the internal splines. If you find a difference between the two. The NP231 transfer case
used two styles of front input bearings. The early transfer case used a wide bearing and the
later model used a narrow bearing. This new input gear is designed for only the early style
case. New Process changed the bearing and gear pitch design in 1995. The center photo
below show a later model input compared to a early.

Once you have verified that you have the same style input gear, install the gear into the planetary, install the snap ring. Re-install the planetary
assembly into the case and secure the input to the bearing with the front snap ring. Note: The only part you should have left out of the case
is the old input gear. During reassembly, make sure the oil return hole matches the front retainer hole.

TRANSMISSION INSTALLATION INFORMATION:

Before assembling, verify that the transmission has a 27 spline output shaft and the stickout is approximately 4.50". If shaft is longer, it may need
to be shortened slightly to prevent bottoming out in
the NP231 input shaft. Install the new reluctor ring

with the set collar side going on the shaft first. Before
tightening this clamp, trial fit the 51-0405 adapter plate
onto the back of the 4L60E transmission. With the
adapter set on the back of the transmission, install the
300619 reluctor sensor into the adapter casting. The
300619 sensor should line up over the teeth of the
reluctor clamp. When you obtain this location, remove
the adapter housing, making sure not to disturb the
position of the clamp on the shaft. With the clamp now
exposed, tighten the two set screws on the clamp.

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of
the components will void any possible warranty or return privileges. If you do not fully understand the 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 vales,
wiring diagrams and other related equipment. These manuals are normally available at automotive dealerships and parts stores.

ADVANCE ADAPTERS, INC. P/N: 50-0435

P. O. Box 247, 4320 Aerotech Center Way New Item: (01/07)
Paso Robles, CA 93447 PAGE: 4 of 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 03-28-12

GM 4L60E 4WD HEX BOLT PATTERN TO JEEP

NP231 T/C (27-SPLINES) 1995 & NEWER

Loctite on these set screws is recommended.

Trial fit the 51-0405 adapter and 300619 sensor back on the transmission and make sure the reluctor ring teeth and sensor still
line up properly. RTV Blue Silicone should be used to seal the 51-0405 adapter to your 4L60E transmission. Screw the 300619
sensor completely into the 51-0405 casting. With a feeler gauge, check the gap between the sensor and the reluctor ring. This
gap should be around 0.010" to 0.012". Once 0.010" to 0.012" clearance is obtained, loctite the sensor into position.

Sensor note: This sensor will match up with the GM pigtail P/N 12162193 or Carquest P/N TX3A.

Once the 51-0405 is installed, install the 4 metric studs into the this adapter. Install the o-ring gasket on the 51-9111 adapter and
bolt it to the 51-0405 casting. NOTE: The output shaft on the transmission should have a slight stick out past the adapter with the
(51-9111) casting installed. The stock NP231 studs should be retained to install the transfer case to the new adapter kit. The casting
has two rotations options.

SPECIAL NOTE: The components packaged in this kit have been assembled and machined for specific types of conversions. Modifications to any of
the components will void any possible warranty or return privileges. If you do not fully understand the 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 vales,
wiring diagrams and other related equipment. These manuals are normally available at automotive dealerships and parts stores.