Transmission. shifter mount 7" " " 2.125" 7.625" Mitsubishi Transmissio n to NP231J Adapter 1" 1" " 1.25" 0.5" 0.625" 0.

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1 TITLE LABEL DATE MITSUBISHI MONTERO SPORT TRANSFER CASE SWAP Drive Train Assembly Side 2/2/2008 Mitsubishi V5MT-3 5-Speed Transmission to NP23J Box4Rocks 2.72: Doubler and NP23J Tera Low23 4: Transfer Case " Transmission shifter mount Factory Transmission shift rail REVISED 5/5/2008 FRONT.25".875" 7" " 5".5" " 2.5" 0.75" " 0.875" 2.25" 0.75" 7.625".75" Tera Low23 NP23J Transfer Case Box4Rocks NP23J Doubler Mitsubishi Transmissio n to NP23J Adapter Factory Mitsu Tail Shaft Housing Mitsubishi V5MT 5-speed Transmission 4.25".75" Mitsubishi V5MT 5- speed Manual Transmission Transfer Case 0.5" Transfer case back plate for Box4Rocks doubler Clocking ring for Box4Rocks doubler.375" " " ".25" 0.5" 3.5".875" 2.75" 5.25" Mitsubishi V5MT-3 transmission output to NP23J 23 spline input stub shaft? 6.325" 0.75" 0.625" PARTS 2006 Jeep Wrangler Unlimited Automatic NP23J 23 spline input 6.5" Tera Low23 Kit 23 spline input?" Tera Flex ultra-short SYE Measurments are approximate to within 0.25". Drawing not to scale.

2 Drive Train Assembly Top View 3.875".4375" FRONT Mitsubishi V5MT 5-speed Transmission.5" " Torsion Bar Mount Cross Member Mitsubishi V5MT 5-speed Transmission

3 Tera Low23 Dimensions Tera Low23 NP23J Front Case Half Dimensions Ø

4 Rear Transfer Case Support LABEL Top View LABEL Passenger Side View FRONT Tera Low23 NP23J Transfer Case Box4Rocks NP23J Doubler " 7.75" Transfer case support Ø Box4Rocks Clocking Ring Jeep TJ Transmission Mount

5 Transfer case support CAD Tera Low23 NP23J, Box4Rocks doubler NP23J transfer case support REVISION HISTORY REV DATE APPROVED (support - piece) (base - piece) R O.4840 O (top - piece) R O R R (gusset - 3 piece) Transfer case support is slotted to allow for some adjustability and access to chamfered bolt. Recess in plate needs to be cut or ground at assembly time for lower right hand doubler case bolt. 3/6" mild steel NAME DRAWN CHECKED ENG APPR MGR APPR DATE edward.shephard 04/6/08 SOLID EDGE UGS - The PLM Company TITLE Transfer case supp SIZE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN D DWG NO REV INCHES.2 ANGLES ±X.X FILE NAME: NP23 transfer case support rev 2.d 2 PL ±X.XX 3 PL ±X.XXX SCALE: WEIGHT: SHEET OF

6 Transfer Case Shift Assembly Tera Low23 Shift Cable Assembly Quick Disconnect Ball Joint Connector PN# LABEL Cable/Shifter Connection 2.625" 6.25" 5.25" 0.5".5" Bulkhead cable bracket.00 Conduit 0.97" 0.47" 0.69" 0.325" " " End rod /4"-28x" Swivel support tube Threaded conduit cap 5/8"-8x.5" Quadco Q Series push-pull controler LABEL Cable/Transfer Case Connection 0.5" 2.625" Conduit.5" 5.25" 6.25" " Threaded pivot PN# " Threaded conduit cap 5/8"-8x.5" Swivel support tube ITEM QTY. PART NO " End rod /4"-28x" Rod end bearing PN# " " " ITEM QTY. PART NO. Light duty push-pull cable 75Lb@5" Max Bellows adapter ring Quick disconnect ball joint connector 7 Bulkhead cable bracket (5/8") 3 5/6"-24 Nyloc nut 8 Quadco Q5 self-locking control Rod end bearing ¼ -28x.75" ¼ -28x.56" 9 ¼ -28 Nyloc nut Bellows LD 0 * Part descriptions in green have been received.

7 Quadco Q5 Controller Tera Low23 Shifter Assembly

8 Transfer Case Shift Lever Pivot CAD Tera Low23 NP23J Extended Shift Lever Pivot ( pieces) gauge mild steel Extended ½ - output lever for the Quadco Q5 and Q36 cable controllers. Necessary to clear tunnel bottom. Extended length decreases shift lever throw and compensates for shortened sector shift lever. NAME DATE SOLID EDG DRAWN Edward Shephard 03/25/08 UGS - The PLM Company CHECKED TITLE ENG APPR Tera Low23 sh MGR APPR SIZE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES D DWG NO REV ANGLES ±X.X FILE NAME: Tera Low23 shift lever pivot.dft 2 PL ±X.XX 3 PL ±X.XXX SCALE: WEIGHT: SHEET OF

9 Doubler Case Shift Assembly NP23J Doubler Case Shift Cable Assembly Tuthill Unidrum CH240, LD, Upper Left cable exit Apx. 35 degrees for full 3" of travel. Cable output is rotated to the top for use rather than at the bottom as is shown here Acrobat Document LABEL Cable/Transfer Case Connection 9.8" Conduit.5" 4.43" 4" 0.9" " Threaded pivot PN# " Threaded conduit cap 5/8"-8x.5" Swivel support tube 0.625" ITEM QTY. PART NO. End rod /4"-28x" Rod end bearing PN# " "-28 ITEM QTY. PART NO. 0.25" UDI Tuthill Unidrum CH240, UL, 3" travel, 46" 6 Clutch push rod boot Jeep CJ 2 ¼ -28 Nyloc nut 7 Clutch push rod boot retainer Rod end bearing ¼ -28x.75" ¼ -28x.56" Jeep CJ Bellows LD Bellows adapter ring 0 * Part descriptions in green have been received.

10 REV REVISION HIST DAT Transfer Case and Doubler Shifter Bracket NP23J and Box 4 Rocks doubler driver side tunnel shifter(s) mount bracket. 90 degree bend R.200 R R O O2.000 weld line R R O gauge mild steel NAMEDATE DRAWN edward.shephard 03/9/09 SOLID CHECKED UGS - Th TITLE ENG APPR Doubler and MGR APPR SIZE DWG NO UNLESS OTHERWISE SPECIFI A DIMENSIONS ARE IN MILLIMET ANGLES ±X.X FILE NAME: Do 2 PL ±X.XX 3 PL SCALE:WEIGHTS ±X.XXX

11 Doubler Case Cable Bracket 90 degree bend REVISION HISTORY REV DATE APP Box 4 Rocks Doubler Case Cable Shift Bracket Assembly R R.25 (2 pieces) gauge (2 pieces) O.250 R R.375 NAME DRAWN CHECKED ENG APPR MGR APPR DATE edward.shephard 05/03/09 SOLID E UGS - The PL TITLE Doubler cable b SIZE DWG NO UNLESS OTHERWISE SPECIFIED A DIMENSIONS ARE IN MILLIMETERS ANGLES ±X.X FILE NAME: Doubler ca 2 PL ±X.XX 3 PL SCALE:WEIGHT:SHEET ±X.XXX

12 Doubler Case Cable Bracket REVISION HISTORY REV DATE APPROVED NP23J Doubler Case Cable Shift Bracket Assembly (2 pieces) 4.48 (bracket shape) R ( pieces) R.25 R O R R.25 O.250 O gauge NAME DATE SOLID ED DRAWN Edward Shephard 04/0/08 UGS - The PLM Company CHECKED ENG APPR MGR APPR TITLE NP23 doubler c SIZE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES D DWG NO REV.0 ANGLES ±X.X FILE NAME: NP23 doubler case cable bracket.d 2 PL ±X.XX 3 PL ±X.XXX SCALE: WEIGHT: SHEET OF

13 Tera Low23 Shift Cable Bracket CAD Tera Low23 NP23J Shift Cable Bracket ( pieces) ( pieces) R R R Gauge

14 Transfer Case Shift Levers Tera Low23 NP23J, Doubler NP23J Shift Levers NP23J doubler shift lever ¼ thick cold rolled Shortened sector shift lever for the NP23 transfer case. Keyway has been rotated to position lever pointing towards the top of the transfer case; allows full throw of the without cable missalignment. Lever has been shortened to decrease lever travel. Tera Low23 NP23J shift lever

15 Transfer Case Shift Levers CAD Tera Low23 NP23J, Doubler NP23J Shift Levers ( pieces) ( pieces) 0 /4" mild steel NAME DRAWN CHECKED ENG APPR MGR APPR DATE Edward Shephard 03/20/08 SOLID EDGE UGS - The PLM C TITLE NP23J shift le SIZE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN D DWG NO REV INCHES ANGLES ±X.X FILE NAME: NP23J shifter levers.dft 2 PL ±X.XX 3 PL ±X.XXX SCALE: WEIGHT: SHEET OF

16 Doubler Shift Cable Tunnel Trim Plate CAD Doubler Shifter Cable Tunnel Boot Trim Plate ( pieces)

17 REVISION HISTORY REV DATE AP LABEL Tera Low23 Transfer Case Shifter Mount Plate Tera Low23 transfer case shifter mounting plate - tunnel ( piece) (2 pieces) O O R O.3290 R R R.250 (4 piece) gauge NAME DATE SOLID DRAWN edward.shephard 05/08/08 UGS - The PLM Co CHECKED ENG APPR MGR APPR SIZE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES D DWG NO ANGLES ±X.X FILE NAME: Tera Low23 shifter mou 2 PL ±X.XX 3 PL ±X.XXX SCALE: WEIGHT: SHEET TITLE Tera Low23

18 Doubler Case Sight Tube Assembly NP23J Doubler Case Sight Tube Assembly Sight-tube for Box4Rocks Doubler 4x4) There is a clearance issue involving the sight tube fitting and the Terra Low23 housing. The Terra Low23 housing extends up to the fitting possibly requiring relocation of the hole slightly towards the end of the plate (direction of the blue arrow) or by using a different fitting (silver press-to-fit fittings shown in the Dana 300 pictures to the right). ITEM QTY. PART NO K223 Push-to-Conn Fitting Swvl 90 Deg Elbow 2 5/6" Tube OD X /4" NPTF Male 3 25' 8359K5 High-Strength Clear Nylon Tubing.242" 4 ID, 5/6" OD,.035" Wall Thickness 5

19 NP23 Transfer Case Diagram NP23 transfer case diagram with labeled components