"New Process" Transfer Case Identification Information
This page reflects information on XJ / Jeep Cherokee New Process chain driven transfer cases. This information is intended to assist you in primarily determining what spline count a given transfer case will have WITHOUT seperating the transfer case from the transmission to physically count the splines. This information may also assist you in finding a transfer case with the correct spline count where the spline count of the donor vehicle's transfer case may be unknown or thought to be different than the original case.
(Many thanks to PhatXJ on JeepsUnlimited’s Cherokee Forum for
providing this picture as a reference!)
- As a general rule - if you have an HO based Jeep vehicle with an open cooling system (radiator cap up front), your spline count is 23.
- If you have a Renix based Jeep with a closed cooling system (coolant bottle on firewall), your spline count is 21.
- Keep in mind that there were some 'transition year' XJ's built that had Renix engines during the HO model year. (Just be aware of this and that your friendly neighborhood Jeep engineer may well deserve a sock in the nose if your XJ is one of these...)
 Transfer Case Identification Guide from "Gears" magazine article
that covers New Process & Borg-Warner transfer
cases. |
"New Process" Transfer Case Identification Chart
The following chart is compiled entirely from contributed information... any data you can add will help validate this info. Unless otherwise noted all model year information is for XJ model Jeeps.
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Additional Information | ||||||||
| Model Year | Tranny Ident. | Tranny Type | Confirmed Transmission Output Shaft Splines | Output Shaft Length | Transfer Case Type | Assembly Number | Serial Number | Transfer Case Gear Ratio | Misc Info From Tags. | NOTE! These are the TYPICAL configurations and like all things Jeep should not be considered 'the last word'. |
| 1999 TJ DONOR VEHICLE (4-Cylinder Engine ONLY!) |
AX-5, AX15, NV3550 | Manual | THIS IS A SWAP FOR RENIX 4.0L XJ 231J with 21 spline transfer cases ONLY! | THIS SWAP APPLIES TO HO 4-CYLINDER TJ DONORS TO RENIX 4.0L 6-CYLINDER XJ's ONLY! | ||||||
| 1999 | AW4 | Auto | 231 | 5209 9212 | 1 9 99 16 | 2.72 | C-161117AL C-16118AN C-20365 | HO Engine Open Cooling System |
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| 1991 | AW4 | Auto | 23 | 242J | 5300 7856 | 5 16 91.2 | 2.72 | C 16119 4 | HO Engine Open Cooling System |
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| 1989 | AW4 | Auto | 21 | 242J | 5390 6098 | 1 18 89.1 | 2.72 | C-16119 K1 | Renix Engine, Closed Cooling System | |
| 1989 | 21 | 2 1/8 | 242J | 5300 6097 | 4 6 89.3 | 2.72 | C-16119 K1 | Renix Engine, Closed Cooling System | ||
| 1990 | 21 | 242J | 5300 8223 | 4 26 90.2 | 2.72 | Renix Engine, Closed Cooling System | ||||
| 1989 | 21 | ?? 09104 ?? | 2.72 | C-16122 | Renix Engine, Closed Cooling System | |||||
| 1987 | AW4 | Auto | 242 AMC | 89530 04269 | 1 28 87 2 | 2.72 | C-16122 C-16119 2 C-16313 | Renix Engine, Closed Cooling System | ||
| 1999 | 23 | 231J | 5209 9212 | 11 26 98 1C | 2.72 | HO Engine Open Cooling System |
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| 1996 | AW4 | Auto | 231J | 5209 8480 | 2 20 96.1 | 2.72 | HO Engine Open Cooling System |
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| 1996 | 23 | 231J | 5209 8480 | 44 96 3 | 2.72 | HO Engine Open Cooling System |
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| 1990 | AW4 | Auto | 231 | Renix Engine, Closed Cooling System | ||||||
| 1987 | AW4 | Auto | 21 | 241C
(* See note below.) |
NO TAG | 2.72 | C-161117 C-16118L C-16220 | |||
| 1987 | 21 | 231 AMC | 89530 04301 | 4 6 87 1 | 2.72 | |||||
| 1991 | AX-15 | Manual | 23 | 231J | 5300 8209 | 10 23 90.1 | 2.72 | Renix Engine, Closed Cooling System | ||
| 1987 | BA-10 | Manual | 21 | 231 | ||||||
| 1986 | AX-5 | Manual | 207 | GM V-6, Open Cooling System | ||||||
| 1984 | Manual | 207 AM 2 | 89500 01520 | 11 15 83 | 2.61 | GM V-6, Open Cooling System | ||||
| 2.8L GM V-6's | 904 | Automatic | 23 spline | |||||||
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NOTE!: * Transfer cases with a * may be either an example of the factory's "what do we have on the shelf that will fit" mentality... or a transfer case swap (from another vehicle) by some previous owner of these XJ's. Please note that the additional information does not cover diesel, 4-banger and who knows what other combo's here... it's all generic and only covers the basics of:
The engine and cooling system
information is to assist those who need a little help identifying what is in
their own vehicle. (That seems to come up a lot on the boards.) Once a tranny
and transfer case is sitting on the shelf it becomes difficult to figure out
for newbie & old-hand alike to determine what the spline count is at a
glance.... that's where this chart comes in. If we can build a decent database
that gives a means to 'read' the tags at a glance then we can scan the racks in
a salvage yard, grab a tranny & transfer case and go without having to
check spline counts first. |
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Thanks to 'Mack' on JU for forwarding me this LINK to a site containing LOTS of data on input shaft lengths, etc in their Transfer Cases ‘Products For Sale’ table. You'll have to dig through their product table a bit but there is a lot of information there if you know what you are looking for. |
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| 1984 - 1987 | NP207 | "Command-Trac" | Part-Time | 2.61:1 | ||
| 1984 - 1987 | NP228 | "Selec-Trac" | Full-Time | 2.72:1 | ||
| 1984 – 1987 | NP229 | "Selec-Trac" | Full-Time | 2.72:1 | ||
| 1987 - 2001 | NP231 |
"Command-Trac" |
Part-Time | 2.72:1 | 26 splines (Same as D44 & D30 pinion. Also same as both outputs of D300 transfer case.) |
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| 1987 – 2001 | NP242 | "Selec-Trac" | Part-Time / Full-Time | 2.72:1 | ||
Please contribute your transfer case information!Please forward transfer case data to: Or (Please use the following format if at all possible! Thanks!)
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If you have pics of your own repairs or can suggest other methods - please contribute your ideas (and pictures) to this article!
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Revised on:
September 23rd, 2007 |
