Advance Adapters 50-6805 User Manual

ADVANCE ADAPTERS INC. P/N: 50-6805

P.O. Box 247, 4320 Aerotech Center Way New Item: (10/04)
Paso Robles, CA 93447 PAGE 1 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 08-16-10

GM 4WD TH350 AUT O T O JEEP NP231

TRANSFER CASE (27-SPLINES) 1995 & UP

KIT CONSISTS OF:

No. Qty Part No. Description

1. 1 51-6800 ADAPTER CASTING (Ref: 711168)

2. 1 716203 1995 & UP 27 SPLINE INPUT

3. 1 *716325A NEEDLE BEARING

4. 1 716511 O-RING

5. 1 716517 GASKET, NP208 T/C

6. 1 716729 SEAL (NAT. #456057) (ADAPTER)

7. 1 716760 NP231 INPUT SEAL

8. 3 723704 3/8" LOCKWASHERS

9. 1 723721 3/8"-16 x 1" H.H.C.S.

10. 4 723729 S.H.C.S. 3/8"-16 x 1-3/4" LG.

11. 2 723730 S.H.C.S. 3/8-16 x 1-1/4" LG.

12. 1 JP001 JEEP INSTRUCTION MANUAL

* INSTALLED AT ADVANCE ADAPTERS

GM TH350 AUTOMATIC

The General Motors TH350 has a case length of 21-1/2", and is available in two different engine-to-transmission bolt
patterns. The case is available with a Chevy bolt pattern that has the top two holes 8-1/4 apart or in a Buick bolt pattern
that has the top two holes 7" apart. The rear side of the transmission case should have a square bolt pattern that uses 4
bolts. There are several various lengths of output shafts that the TH350 transmissions have been furnished with. This kit
is designed around the 4WD version having an approximate output shaft stickout of 1". The rear transmission support is
located in the main case just forward of the tailhousing connection. This can be used for supporting this crossmember on
some installations, but most of our kits provide support on the new adapter housing.

OPTIONAL ITEMS:

Part No. Description

716008 Crossmember mount

NOTE: This kit will not work

with a Tera low 4:1 NP231 kit.

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.

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 that is used on all TH350 installations.

This adapter can be used on either Jeep Wranglers 1995 & newer or Jeep Cherokees 1995 & newer. The only difference
is the transfer case shifter linkage. The adapter is 1-1/2" thick and will provide an overall transmission assembly length
of 23". On this conversions, you can anticipate driveshaft modifications.

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.

ADVANCE ADAPTERS INC. P/N: 50-6805

P.O. Box 247, 4320 Aerotech Center Way New Item: (10/04)
Paso Robles, CA 93447 PAGE 2 OF 4
Telephone: [phone] Fax: [phone] Page Rev . Date: 06-01-04

GM 4WD TH350 AUT O T O JEEP NP231

TRANSFER CASE (27-SPLINES) 1995 & UP

Jeep Wranglers 1995-96 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.

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 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.