Transmission and Transfer Case — part 4 of 4 — 1996 Jeep Grand Cherokee ZJ Service Manual
← Contents 1 2 3 4
Pages 1339–1379 · 41 pages · 2 words repaired
(23) Remove mainshaft from clutch sleeve and input gear pilot.
(24) Rotate shift sector so sector teeth face upward (Fig. 39).
(25) Remove range fork, rail and clutch sleeve as assembly (Fig. 40). Lift shift rail upward, rotate fork out of shift sector and remove assembly.
(26) Turn front case on side so front bearing retainer is accessible.
(27) Remove front bearing retainer bolts (Fig. 41). (28) Remove front bearing retainer as follows: Loosen retainer with flat blade screwdriver to break sealer bead. Then remove retainer from case and gear. To avoid damaging case and retainer, position screwdriver blade only in slots provided in retainer (Fig. 42).
(29) Remove snap ring that retains input gear shaft in front bearing (Fig. 43).
(30) Remove input and low range gear assembly (Fig. 44).
(31) Remove range lever locknut and remove lever and washer from shift sector shaft (Fig. 45).
(32) Remove shift sector. Rotate and tilt sector as needed to remove it (Fig. 46).
Removal
(33) Remove magnet from case.
TRANSFER CASE ASSEMBLE
Lubricate the transfer case components with the Mopar Dexron II during assembly operations.
Use petroleum jelly to lubricate and hold mainshaft needle roller bearings and spacers in place. Petroleum jelly can also be used to lubricate seals, bushings and bearings during assembly.
Gaskets are not used in the NV249 transfer case. Instead, the mating surfaces of the case halves, retainer and extension are sealed with Mopar Gasket Maker, silicone adhesive/sealer, or Loctite 518.
(1) Support front case on wood blocks. Position case so sector shaft bore and input gear bearing are accessible.
(2) Lubricate sector shaft, O-ring and shaft bore (in case) with petroleum jelly.
(3) Install sector in case (Fig. 46).
(4) Lubricate shift rail bushing with light coat of petroleum jelly, or transmission fluid. Do not over lubricate bushing. Excess lubricant will flow into bottom of bushing bore and prevent shift rail from fully seating; this can also make it difficult to seat rear case on front case.
(5) Lubricate bearings and seals in front case with transmission fluid or petroleum jelly.
(6) Install magnet in case. (7) Align and install low range-input gear assembly in front case (Fig. 47). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.
(8) Install snap-ring to hold input/low range gear into front bearing (Fig. 48).
(9) Install new pads on range fork (Fig. 49). (10) Lubricate range fork pads with light coat of petroleum jelly.
(11) Install clutch sleeve in range fork (Fig. 49). (12) Install assembled range fork and clutch sleeve (Fig. 50). Insert range fork pin in sector. Then rotate sector and seat clutch gear in low range gear.
(13) Verify that range fork rail is seated in case bushing and that clutch sleeve is properly engaged in low range gear.
(14) Rotate sector to Neutral position.
(15) Install new O-ring on detent plug (Fig. 51). (16) Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.
(17) Install detent plunger, spring and plug (Fig. 51). (18) Verify that plunger is properly engaged in sector.
(19) Insert mainshaft into input gear pilot bearing. (20) Lubricate front output shaft-sprocket assembly, drive chain and drive sprocket with transmission fluid.
(21) Assemble drive chain, drive sprocket and front output shaft (Fig. 52).
(22) Start drive sprocket on mainshaft. (23) Guide front shaft into bearing and drive sprocket onto mainshaft drive gear (Fig. 52).
(24) Install drive sprocket snap ring (Fig. 53). (25) Lubricate mainshaft splines with transmission fluid.
(26) Install coupling on mainshaft (Fig. 54).
And Drive Sprocket
(27) Install coupling retaining snap ring first (Fig. 54). Be sure snap ring is fully seated before proceeding.
(28) Install oil pump locating snap ring on mainshaft (Fig. 54).
(29) Clean sealing flanges of front case and rear case with a wax and grease remover.
(30) Install new O-ring on flanged end of oil pickup tube.
(31) Install oil pickup tube in rear case. Be sure tube is seated in case notch as shown (Fig. 55).
(32) Apply 3 mm (1/8 in.) wide bead of Mopar gasket maker, silicone adhesive sealer, or Loctite 518 to mounting flange of front case. Work sealer bead around bolt holes as shown (Fig. 56).
Installation
(33) Align and install rear case on front case (Fig. 57).
(34) Verify that oil pickup tube is still seated in case notch and tube end is pointed toward mainshaft (Fig. 58).
(35) Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers (Fig. 59). (36) Tighten case bolts to 27-34 N·m (20-25 ft. lbs.) torque.
(37) Install oil pump (Fig. 60).
(38) Insert oil pickup tube in pump (Fig. 61). (39) Install rear bearing on mainshaft (Fig. 61). Locating ring groove in bearing goes toward end of mainshaft.
(40) Install rear bearing retaining snap ring (Fig. 62). (41) Install speedometer drive gear (Fig. 63).
(42) Install rear bearing locating ring in rear retainer, if ring was removed during overhaul.
(43) Apply 3 mm (1/8 in.) wide bead of Mopar gasket maker, silicone adhesive sealer, or Loctite 518 to mounting surface of rear retainer. Allow sealer to set-up slightly before proceeding.
(44) Slide rear retainer onto mainshaft (Fig. 64). (45) Spread rear bearing locating ring and slide rear retainer into place on rear case (Fig. 65).
(46) Install and tighten rear retainer bolts to 27-34 N·m (20-25 ft. lbs.).
(47) Install locating ring access cover and gasket (Fig. 66). Tighten plate attaching screws to 10 N·m (85 in. lbs.) torque.
(48) Apply 3 mm (1/8 in.) wide bead of Mopar Gasket Maker, silicone adhesive sealer, or Loctite 518 to mating surface of front bearing retainer. Allow sealer to set-up slightly before installing retainer.
(49) Install front bearing retainer (Fig. 67). Tighten retainer bolts to 16-24 N·m (12-18 ft. lbs.) torque.
Gasket
(50) Install new seal washer on front output shaft (Fig. 68).
(51) Install yoke and new yoke nut on front output shaft (Fig. 69).
(52) Tighten yoke nut to 122-176 N·m (90-130 ft. lbs.) torque. Use Tool C-3281, or similar tool to hold yoke while tightening yoke nut.
(53) Install range lever, washer and locknut on sector shaft (Fig. 70). Tighten locknut to 27-34 N·m (20-25 ft. lbs.) torque.
(54) Install drain plug. Tighten plug and switch to 41-54 N·m (30-40 ft. lbs.) torque. (55) Install and tighten indicator switch to 20-34 N·m (15-25 ft. lbs.) torque.
(56) Level transfer case and fill it with Mopar Dexron II. Correct fill level is to bottom edge of fill plug hole.
(57) Install and tighten fill plug to 41-54 N·m (30-40 ft. lbs.) torque.
INPUT AND LOW RANGE GEAR
DISASSEMBLE
(1) Remove snap ring that retains input gear in low range gear (Fig. 71).
(2) Remove retainer (Fig. 72). (3) Remove front tabbed thrust washer (Fig. 73). (4) Remove input gear (Fig. 74).
(5) Remove rear tabbed thrust washer from low range gear (Fig. 75).
INPUT AND LOW RANGE GEAR ASSEMBLE
(1) Lubricate gears and thrust washers (Fig. 76) with recommended transmission fluid.
(2) Install first thrust washer in low range gear (Fig. 76). Be sure washer tabs are properly aligned in gear notches.
(3) Install input gear in low range gear. Be sure input gear is fully seated.
(4) Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.
(5) Install retainer on input gear and install snap ring.
CLEANING AND INSPECTION
NV249 COMPONENTS
Clean the transfer case components with parts cleaning solvent. Flush the oil passages in the cases and drivetrain components with solvent. This will help remove dirt and particles from these passages.
Dry the transfer case components with compressed air or allow them to air dry on clean shop towels.
Apply compressed air through all oil passages in the cases and gear components to clear them of any residue.
MAINSHAFT
Examine the mainshaft components carefully for evidence of wear or damage.
Replace the thrust washers if worn or damaged. Replace the mainshaft and sprocket gears if the teeth or gear bores are worn or damaged.
Replace the mainshaft bearings if worn, flat spotted, brinelled, or damaged in any way.
Replace the mainshaft if it exhibits wear or damage to the bearing surfaces, splines or gear teeth.
INPUT AND LOW RANGE GEARS
Inspect the low range gear pinions and pinion pins. Replace the low range gear if any of the pins or pinions are worn or damaged.
Inspect the thrust washers, retainer and snap ring. Replace the snap ring if bent, or distorted. Replace the thrust washers and retainer if worn, cracked or damaged in any way.
Examine the input gear carefully. Be sure the gear teeth and bearing surfaces are in good condition. Replace the gear if wear or damage is evident.
Check the input gear pilot bearing. Rotate the bearing and check for roughness or noise. Also check bearing position in the bore. The bearing should be recessed approximately 2.5 mm (0.100 in.) below the top edge of the bore. The bearing should not be seated at the bottom of the bore. Replace the bearing if worn, or roughness is evident. Replace both the gear and bearing if the bearing is a loose fit in the bore.
Gear Cases And Extension
Examine both case halves and the extension carefully. Replace the extension or either case half if wear, cracks, or other damage is evident.
Check condition of the low range annulus gear and the shift rail bushing in the front case (Fig. 77). The low range annulus gear is not a serviceable part. Replace the gear and case as an assembly if the gear is loose, worn, or damaged. The shift rail bushing is a serviceable part and can be replaced if necessary.
Check the bushing in the rear extension. Replace the bushing if worn or scored. A shop press and universal type bushing driver set can be used for replacement purposes.
Examine the sealing surfaces of both case halves and the extension. Small burrs, or scratches on these surfaces can be reduced with crocus cloth or a fine tooth file.
Examine condition of the shift rail bushing in the front case. If the bushing is worn or damaged, it can be removed with a blind hole type puller. A replacement bushing can be installed with a suitable size driver. Recess the bushing slightly below the edge of the bore but do not seat it all the into the case.
Geartrain
The differential pinion gears and thrust washers are serviceable components and can be replaced if worn or damaged. The differential cases are also serviceable but must be replaced as a set if either case is damaged.
Inspect the mainshaft splines, gear teeth and bearing surfaces carefully for evidence of wear, or damage. Replace the shaft if necessary. do not attempt to salvage it if damaged.
The shift rail and range fork are an assembly. Replace both parts if either is damaged. However, the nylon pads in the fork can be replaced if worn, or cracked.
Inspect the transfer case snap rings closely. Do not attempt to salvage a distorted snap ring by straightening or reshaping it. Replace any snap ring that is distorted, or worn.
Inspect the low range gear, input gear and the gear thrust washers retainer, and snap ring. The low range gear is serviced as an assembly only. Replace the gear if the case or pinions are damaged.
During inspection, also make sure the seal surface of the input gear is in good condition. Minor nicks on this surface can be reduced with crocus cloth. However, replace the gear if the seal surface is severely scored or worn.
The speedometer gear should be replaced if worn, cracked, or if the small spline teeth are worn.
OIL PUMP AND VISCOUS COUPLING
The oil pump and viscous coupling are not serviceable components. Replace the coupling as an assembly if it is leaking or damaged. Replace the oil pump as an assembly if the gear teeth are worn, or if the pump has become damaged.
BEARINGS AND SEALS
The transfer case seals should be replaced during overhaul. Use new seals in the input gear bearing retainer, front case and rear extension. Also replace the yoke seal washer and the detent plug O-ring.
Check condition of each transfer case bearing. Replace any bearing exhibiting signs of roughness, wear, or damage.
Bearing and seal replacement is described in the Transfer Case Bearing And Seal Replacement procedures.
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into Neutral position. (2) Raise vehicle on hoist that will allow all four wheels to rotate freely.
(3) Loosen trunnion lock bolt (Fig. 78). Loosen bolt enough so selector rod slides freely in trunnion.
(4) Verify that shift lever on transfer case is in Neutral position.
(5) Tighten trunnion lock bolt to 11-20 N·m (96-180 in. lbs.) torque.
(6) Lower vehicle enough for entry into driver seat but keep all wheels off shop floor.
(7) Verify correct linkage adjustment. Start engine, shift transmission into gear and shift transfer case into all ranges. Be sure transfer case is fully engaged in high and low range. Readjust linkage if necessary.
(8) Shut engine off and lower vehicle completely.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE Bolt, crossmember . . . . . .41-47 N·m (30-35 ft. lbs.) Plug, Detent . . . . . . . . . . .16-24 N·m (12-18 ft. lbs.) Plugs, drain/fill. . . . . . . . .41-54 N·m (30-40 ft. lbs.) Switch, Electric . . . . . . . .20-34 N·m (15-25 ft. lbs.) Bolts, front brg. retainer.16-24 N·m (12-18 ft. lbs.) Bolts, case half . . . . . . . . .27-34 N·m (20-25 ft. lbs.) Nut, output yoke . . . .122–176 N·m (90-130 ft. lbs.) Bolts, rear extension . . . .27-34 N·m (20-25 ft. lbs.) Lock-nut, shift . . . . . . . . .27-34 N·m (20-25 ft. lbs.) Bolt, shift rod. . . . . . . . .11-20 N·m (96-180 in. lbs.) Nuts, T-case mount stud .33-41 N·m (24-30 ft. lbs.) Bolt, U-joint clamp. . . . . .16-22 N·m (12-16 ft. lbs.)
SPECIAL TOOLS
NV249 TRANSFER CASE
Installer—5066
Installer—6952
Installer—6953
Installer—6954
Remover—6957
Adapter—7794–A
Installer—7823
Slide Hammer—C-637
Installer—C-3972-A
Remover—C-3985-B
Handle—C-4171
Installer—C-4735
TRANSFER CASE IDENTIFICATION
A circular ID tag is attached to the rear case of each transfer case (Fig. 2). The ID tag provides the transfer case model number, assembly number, serial number, and low range ratio.
The transfer case serial number also represents the date of build.
RECOMMENDED LUBRICANT AND FILL LEVEL
Recommended lubricant for the NV 242 transfer case is Mopart Dexron II, or ATF Plus. Approximate lubricant fill capacity is 1.35 liters (2.85 pints).
The fill and drain plugs are both in the rear case (Fig. 2). Correct fill level is to the bottom edge of the fill plug hole. Be sure the vehicle is level to ensure an accurate fluid level check.
NV242 DIAGNOSIS
DIFFICULT TO SHIFT OR loose components as necessary.
WILL NOT SHIFT INTO
DESIRED RANGE
(2) Insufficient or incorrect lubricant. (2) Drain and refill to edge of fill hole with DEXRON
or MOPAR-MERCON ® Automatic
Transmission Fluid.
(3) Internal components binding, worn or damaged. (3) Disassemble unit and replace worn or damaged
components as necessary.
TRANSFER CASE NOISY (1) Insufficient or incorrect lubricant. (1) Drain and refill to edge of fill hole with DEXRON
IN ALL DRIVE POSITIONS or MOPAR-MERCON® Automatic
Transmission Fluid. Check for leaks and repair if
necessary Note: If unit is still noisy after
drain and refill, disassembly and
inspection may be required to locate
source of noise.
LUBRICANT LEAKING (1) Transfer case overfilled. (1) Drain to correct level.
FROM OUTPUT SHAFT
SEALS OR FROM VENT
(2) Vent closed or restricted. (2) Clear or replace vent if necessary.
(3) Output shaft seals damaged or installed (3) Replace seals. Be sure seal lip faces interior of
incorrectly. case when installed. Also be sure yoke seal
surfaces are not scored or nicked. Remove scores
and nicks with fine sandpaper or replace yoke(s)
if necessary.
TRANSFER CASE WILL (1) Incomplete shift due to drivetrain (1) Driver must momentarily release the
NOT SHIFT THROUGH torque load. accelerator pedal to complete the shift.
4X 4 PART-TIME
RANGE (2) Incorrect tire pressure(s). (2) Inflate all tires equally to correct pressure.
(Light Remains On).
(3) Excessive tire wear. (3) Switch tires — Install the two tires with
; . the most wear (one on the front axle
(4) Excessive vehicle loading. and one on the rear axle).
(4) Check vehicle loading — Do not exceed
the vehicle's GVW.
J9121-435
REMOVAL AND INSTALLATION
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 4L. (2) Raise vehicle. (3) Loosen adjusting trunnion locknut and slide shift rod out of trunnion (Fig. 3). If rod lacks enough travel to come out of trunnion, push trunnion out of torque shaft.
(4) Lower vehicle. (5) Remove console. Refer to park brake section in Group 5 for procedures.
(6) Remove screws attaching lever assembly to floorpan and remove assembly and shift rod (if left attached).
INSTALLATION
(1) If shift rod was not removed from lever assembly, work rod down through floorpan opening. Then position lever assembly on floorpan and install assembly attaching screws.
(2) Install console. (3) Raise vehicle. (4) Connect trunnion to torque shaft arm. Or, slide shift rod into trunnion on range lever. Be sure shift rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then tighten trunnion lock bolt.
(6) Lower vehicle and check transfer case shift operation.
TRANSFER CASE
REMOVAL
(1) Shift transfer case into Neutral. (2) Raise vehicle. (3) Drain transfer case lubricant. (4) Mark front and rear propeller shaft yokes for alignment reference.
(5) Support transmission with jack stand. (6) Remove rear crossmember, or skid plate. (7) Disconnect front/rear propeller shafts at transfer case.
(8) Disconnect vehicle speed sensor wires. (9) Disconnect transfer case linkage rod from range lever.
(10) Disconnect transfer case vent hose and indicator switch harness.
(11) Support transfer case with transmission jack. (12) Remove nuts attaching transfer case to transmission.
(13) Secure transfer case to jack with chains. (14) Pull transfer case and jack rearward to disengage transfer case.
(15) Remove transfer case from under vehicle.
INSTALLATION
(1) Mount transfer case on a transmission jack. Secure transfer case to jack with chains.
(2) Position transfer case under vehicle. (3) Align transfer case and transmission shafts and install transfer case on transmission.
(4) Install and tighten transfer case attaching nuts to 35 N·m (26 ft. lbs.) torque (Fig. 4).
(5) Connect vehicle speed sensor wires, and vent hose.
(6) Connect indicator switch harness to transfer case switch. Secure wire harness to clips on transfer case.
(7) Align and connect propeller shafts. Tighten shaft attaching bolts to 19 N·m (170 in. lbs.) torque.
(8) Fill transfer case with Mopar Dextron II fluid. (9) Install rear crossmember, or skid plate. Tighten crossmember bolts to 41 N·m (30 ft. lbs.) torque.
(10) Remove transmission jack and support stand. (11) Connect shift rod to transfer case range lever. (12) Adjust transfer case shift linkage.
(13) Lower vehicle and verify transfer case shift operation.
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE
DISASSEMBLE
REAR RETAINER REMOVAL AND DISASSEMBLY
(1) Remove output shaft boot. Spread band clamp that secures boot on slinger with a suitable awl. Then slide boot off shaft (Fig. 5).
(2) Using puller MD-998056-A, remove rear slinger (Fig. 6).
(3) Remove slinger stop spacer and snap-ring from output shaft (Fig. 7).
(4) Remove rear seal from retainer (Fig. 8). Use pry tool, or collapse seal with punch to remove it.
(5) Remove rear output bearing I.D. retaining ring (Fig. 9).
(6) Remove rear retainer bolts.
(7) Remove rear retainer. Tap retainer with mallet and pry upward to break sealer bead. Then slide retainer off case and output shaft (Fig. 10).
(8) Remove rear bearing O.D. retaining ring with snap ring pliers. Then tilt pump and slide it off output shaft (Fig. 11)
(9) Remove pickup tube O-ring from pump (Fig. 12) but do not disassemble pump; it is not a repairable part.
(10) Remove seal from oil pump with pry tool.
(11) Remove bolts attaching rear case to front case. A 10 mm, 12 point socket is needed for the spline head bolt (Fig. 13). Note position of the two black finish bolts at each end of the case. These bolts go through the case dowels and require a washer under the bolt head.
(12) Remove rear case from front case (Fig. 14). Insert screwdrivers into slots cast into each end of case. Then pry upward to break sealer bead and remove rear case.
CAUTION: Do not pry on the sealing surface of either case half as the surfaces will become damaged.
(13) Remove oil pickup tube and screen from rear case (Fig. 15).
SPEEDOMETER/YOKE/RANGE LEVER REMOVAL
(1) Remove speedometer adapter. (2) Remove front yoke nut:
(a) Move range lever to 4L position. (b) Remove nut with socket and impact wrench (Fig. 16). (3) Remove yoke. If yoke is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller (Fig. 17). Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged.
(4) Remove seal washer from front output shaft. Discard washer as it should not be reused.
(5) Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft (Fig. 18).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Remove drive sprocket snap ring (Fig. 19).
(2) Remove drive sprocket and chain (Fig. 20). (3) Remove front output shaft (Fig. 21).
SHIFT FORKS AND MAINSHAFT REMOVAL AND DISASSEMBLY
(1) Remove shift detent plug, spring and pin (Fig. 22).
(2) Remove seal plug from low range fork lockpin access hole. Then move shift sector to align low range fork lockpin with access hole (Fig. 23).
(3) Remove range fork lockpin with size number one easy-out tool. Grip easy-out tool with locking pliers and remove pin with counterclockwise, twist and pull motion (Fig. 23).
(4) Remove shift rail by pulling it straight up and out of fork (Fig. 24).
(5) Remove mode fork and mainshaft as assembly (Fig. 25).
(6) Remove mode shift sleeve and mode fork assembly from mainshaft (Fig. 26). Note position of mode sleeve in fork and remove sleeve.
(7) Remove intermediate clutch shaft snap ring (Fig. 27).
(8) Remove clutch shaft thrust ring (Fig. 28). (9) Remove intermediate clutch shaft (Fig. 29).
Removal
(10) Remove differential snap ring (Fig. 30). (11) Remove differential (Fig. 31). (12) Remove differential needle bearings and both needle bearing thrust washers from mainshaft.
(13) Slide low range fork pin out of shift sector slot (Fig. 32).
(14) Remove low range fork and hub (Fig. 33). (15) Remove shift sector (Fig. 34).
(16) Remove shift sector bushing and O-ring (Fig. 35).
INPUT GEAR/LOW RANGE ASSEMBLY REMOVAL AND DISASSEMBLY
(1) Remove front bearing retainer bolts. (2) Remove front bearing retainer. Carefully pry retainer loose with screwdriver (Fig. 36). Position screwdriver in slots cast into retainer.
(3) Remove input gear snap ring (Fig. 37).
(4) Remove input/low range gear assembly from bearing with Tool Handle C-4171 and Tool 7829A (Fig. 38).
(5) Remove low range gear snap ring (Fig. 39). (6) Remove input gear retainer, thrust washers and input gear from low range gear (Fig. 40).
Removal
(7) Inspect low range annulus gear (Fig. 41). Gear is not a serviceable component. If damaged, replace gear and front case as assembly.
(8) Remove oil seals from following components: • rear retainer • oil pump • case halves
Installation
DIFFERENTIAL DISASSEMBLY
(1) Mark differential case halves for reference. (2) Remove differential case bolts. (3) Invert differential on workbench. (4) Separate top case from bottom case. Use slots in case halves to pry them apart (Fig. 42).
(5) Remove thrust washers and planet gears from case pins (Fig. 43).
(6) Remove mainshaft and sprocket gears from bottom case (Fig. 44). Note gear position for reference before separating them.
ASSEMBLE
(1) Lubricate transfer case components with automatic transmission fluid or petroleum jelly (where indicated) during assembly.
CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.
BEARING AND SEAL INSTALLATION
(1) Remove snap ring that retains front output shaft front bearing in case (Fig. 45). Then remove bearing. Use hammer handle, or hammer and brass punch to tap bearing out of case.
(2) Install new front output shaft bearing with Tool Handle C-4171 and Installer 8033A with the tapered cone upward (Fig. 46).
Removal
(3) Install front bearing snap ring (Fig. 45). (4) Install new front output shaft oil seal as follows:
(a) Tap seal into bore until flush with upper edge of case bore. Use Installer 6888 to start seal into place (Fig. 47).
(b) Seat seal 2.03 to 2.5 mm (0.080 to 0.100 in.) below top edge of seal bore in front case (Fig. 48). This is correct final seal position. Use Installer 6888 to final seat seal. Check seal depth with a dial caliper or depth micrometer.
CAUTION: Be sure the front output seal is seated below the top edge of the case bore as shown (Fig. 48). The seal could work loose if not seated to the recommended depth.
Bore
(5) Remove input gear bearing with Tool Handle C-4171 and Remover C-4210 (Fig. 49).
(6) Install snap ring on new input gear bearing. (7) Install new input gear bearing with Tool Handle C-4171 and Remover C-4210. Install bearing far enough to seat snap ring against case (Fig. 50).
(8) Remove input gear pilot bearing with slide hammer and internal puller (Fig. 51).
(9) Install new pilot bearing with suitably sized driver tool.
(10) Install new seal in front bearing retainer with Tool Handle C-4171 and Installer 7884 (Fig. 52).
Replace output shaft rear bearing (Fig. 53). Remove bearing with internal puller and slide hammer.
(12) Install new bearing with Tool Handle C-4171 and Installer 5066. Lubricate bearing after installation.
(13) Install new seal in oil pump feed housing with Special Tool 7888 (Fig. 54).
(14) Install new pickup tube O-ring in oil pump (Fig. 55).
DIFFERENTIAL ASSEMBLY
(1) Lubricate differential components with automatic transmission fluid.
(2) Install sprocket gear in differential bottom case (Fig. 56).
(3) Install differential planet gears and new thrust washers (Fig. 57). Be sure thrust washers are installed at top and bottom of each planet gear.
(4) Install differential mainshaft gear (Fig. 57). (5) Align and position differential top case on bottom case (Fig. 58). Align using scribe marks made at disassembly.
(6) While holding differential case halves together, invert the differential and start the differential case bolts.
(7) Tighten differential case bolts to specified torque.
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assemble low range gear, input gear thrust washers, input gear and input gear retainer (Fig. 59).
(2) Install low range gear snap ring (Fig. 60).
(3) Lubricate input gear and low range gears with automatic transmission fluid.
(4) Start input gear shaft into front case bearing. (5) Press input gear shaft into front bearing. (6) Install new input gear snap ring (Fig. 61). (7) Apply 3 mm (1/8 in.) wide bead of Mopart gasket maker, silicone adhesive sealer, or Loctitey 518 to seal surface of front bearing retainer.
(8) Install front bearing retainer (Fig. 62). Tighten retainer bolts to 16 ft. lbs. (21 N·m) torque.
SHIFT FORKS AND MAINSHAFT ASSEMBLY AND INSTALLATION
(1) Install new sector shaft O-ring and bushing (Fig. 63).
(2) Install shift sector. (3) Install new pads on low range fork, if necessary, (Fig. 64).
(4) Assemble low range fork and hub (Fig. 64). (5) Position low range fork and hub in case. Be sure low range fork pin is engaged in shift sector slot (Fig. 65).
(6) Install first mainshaft bearing spacer on mainshaft (Fig. 66).
(7) Install bearing rollers on mainshaft (Fig. 66). Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
(8) Install remaining bearing spacer on mainshaft (Fig. 66). Do not displace any bearings while installing spacer.
Spacers
(9) Install differential (Fig. 67). Do not displace mainshaft bearings when installing differential.
(10) Install differential snap ring (Fig. 68). (11) Install intermediate clutch shaft (Fig. 69).
(12) Install clutch shaft thrust washer (Fig. 70). (13) Install clutch shaft snap ring (Fig. 71). (14) Inspect mode fork assembly (Fig. 72). Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket (Fig. 72). Replace worn, damaged components.
(15) Install mode sleeve in mode fork (Fig. 73). Then install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.
(16) Install mode fork and mainshaft assembly in case (Fig. 74). Rotate mainshaft slightly to engage shaft with low range gears.
(17) Rotate mode fork pin into shift sector slot.
Installation
(18) Install shift rail (Fig. 75). Be sure rail is seated in both shift forks.
(19) Rotate shift sector to align lockpin hole in low range fork with access hole in case.
(20) Insert an easy-out in range fork lockpin to hold it securely for installation (Fig. 76). Lockpin is slightly tapered on one end. Insert tapered end into fork and rail.
(21) Insert lockpin through access hole and into shift fork (Fig. 76). Then remove easy-out and seat the pin with pin punch.
(22) Install plug in lockpin access hole. (23) Install detent plunger, detent spring and detent plug in case (Fig. 77).
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Install front output shaft (Fig. 78). (2) Install drive chain (Fig. 78). Engage chain with front output shaft sprocket teeth.
(3) Install drive sprocket (Fig. 78). Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft splines.
(4) Install drive sprocket snap ring (Fig. 79).
OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION
(1) Insert oil pickup tube in oil pump and attach oil screen and connector hose to pickup tube. Then install assembled pump, tube and screen in rear case (Fig. 80). Be sure screen is seated in case slot as shown.
(2) Install magnet in front case pocket (Fig. 81).
(3) Apply 3 mm (1/8 in.) wide bead of Mopar gasket maker, silicone adhesive sealer, or Loctite 518 to seal surface of front case.
(4) Align and install rear case on front case. Be sure case locating dowels are in place and that mainshaft splines are engaged in oil pump inner gear.
(5) Install and tighten front case-to-rear case bolts to 41 N·m (30 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.
REAR RETAINER ASSEMBLY AND INSTALLATION
(1) Remove rear bearing in retainer using a hammer handle or a hammer and a brass drift to tap bearing from the retainer.
(2) Install rear bearing in retainer with Tools C-4171 and 5064 (Fig. 82).
(3) Install rear bearing O.D. retaining ring with snap ring pliers (Fig. 83). Be sure retaining ring is fully seated in retainer groove.
(4) Apply bead of Mopart Sealer P/N 82300234, or Loctitey Ultra Gray, to mating surface of rear
retainer. Sealer bead should be a maximum of 3/16 in.
(5) Install rear retainer on rear case. Tighten retainer bolts to 20–27 N·m (15–20 ft. lbs.) torque.
(6) Install rear bearing I.D. retaining ring and spacer on output shaft.
(7) Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
(8) Slide seal onto Seal Protector 6992 (Fig. 84). Slide seal protector and seal onto output shaft.
(9) Slide Installer C-4076-A onto seal protector with the recessed side of the tool toward the seal. Drive seal into rear bearing retainer with installer C-4076-A and handle MD-998323 (Fig. 85).
(10) Install rear slinger with installer C-4076-A and handle MD-998323 (Fig. 85).
(11) Install boot on output shaft slinger and crimp retaining clamp with tool C-4975-A (Fig. 86).
FRONT YOKE AND SWITCH INSTALLATION
(1) Install indicator switch in front case. Tighten switch to 20–34 N·m (15–25 ft. lbs.) torque.
(2) Lubricate yoke hub with transmission fluid and install yoke on front shaft.
(3) Install new seal washer on front shaft. (4) Install yoke on front shaft. Secure yoke with new nut.
CLEANING AND INSPECTION
NV242 TRANSFER CASE
Clean the transfer case parts with a standard parts cleaning solvent. Remove all traces of sealer from the cases and retainers with a scraper and all purpose cleaner. Use compressed air to remove solvent residue from oil feed passages in the case halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent. Shake excess solvent from the screen after cleaning and allow it to air dry. Do not use compressed air.
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the teeth on the sprocket. Minor nicks and scratches can be smoothed with an oilstone, however, replace any part is damaged.
Check the contact surfaces in the sprocket bore and on the mainshaft. Minor nicks and scratches can be smoothed with 320–400 grit emery cloth but do not try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 87). Minor nicks can be dressed off with an oilstone but replace the gear if any teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300–400 grit emery cloth if necessary. Examine the carrier body and pinion gears for wear or damage. The carrier will have to be replaced as an assembly if the body, pinion pins, or pinion gears are damaged.
Check the lock ring and both thrust washers for wear or cracks. Replace them if necessary. Also replace the lock retaining ring if bent, distorted, or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift rail (Fig. 88). Minor nicks on the shift rail can be smoothed with 320–400 grit emery cloth.
Inspect the shift fork wear pads. The mode fork pads are serviceable and can be replaced if necessary. The range fork pads are also serviceable.
Check both of the sleeves for wear or damage, especially on the interior teeth. Replace the sleeves if wear or damage is evident.
REAR RETAINER/BEARING/ SEAL/SLINGER/ BOOT
Inspect the retainer components (Fig. 89). Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the bearing bore. Clean the retainer sealing surfaces with a scraper and all purpose cleaner. This will ensure proper adhesion of the sealer during reassembly.
Replace the slinger and seal outright; do not reuse either part.
Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not
recommended. Also replace the boot if cut or torn. Replace the boot band clamps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the yoke slinger (Fig. 90). This surface must be clean and smooth to ensure proper seal life. Replace the yoke nut and seal washer as neither part should be reused.
Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320–400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.
Examine the drive chain and shaft bearings. replace the chain if stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to remove the gear (Fig. 91)
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and damage. Clean the sealing surfaces with a scraper and all purpose cleaner. This will ensure proper sealer adhesion at assembly. Replace the input retainer seal; do not reuse it.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.
Check the front case mounting studs and vent tube. The tube can be secured with Loctitey 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/ drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position. (2) Raise vehicle. (3) Loosen lock bolt on adjusting trunnion (Fig. 92). (4) Be sure linkage rod slides freely in trunnion. Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully engaged in 4L position.
(6) Tighten adjusting trunnion lock bolt. (7) Lower vehicle.
SPECIFICATIONS
TORQUE
DESCRIPTION TORQUE Plug, Detent . . . . . . . . . . .16–24 N·m (12–18 ft. lbs.) Bolt, Diff. Case . . . . . . . . .17–27 N·m (15–24 ft. lbs.) Plug, Drain/Fill . . . . . . . . .40–45 N·m (30–40 ft. lbs.) Bolt, Front Brg. Retainer. .16–27 N·m (12–20 ft. lbs.) Bolt, Case Half . . . . . . . . .35–46 N·m (26–34 ft. lbs.) Nut, Front Yoke . . . . . .122–176 N·m (90–130 ft. lbs.) Screw, Oil Pump . . . . . . .1.2–1.8 N·m (12–15 in. lbs.) Nut, Range Lever . . . . . . .27–34 N·m (20–25 ft. lbs.) Bolt, Rear Retainer . . . . . .35–46 N·m (26–34 ft. lbs.) Nuts, Mounting . . . . . . . . .35–47 N·m (26–35 ft. lbs.) Bolts, U-Joint . . . . . . . . . . . . . . . .19 N·m (17 ft. lbs.)
SPECIAL TOOLS
NV242
Installer—6888
Installer—C-4076-A
Handle, Universal—C-4171
Installer, Seal—C-4210
Puller, Slinger—MD-998056–A
Installer—MD-998323
Installer, Bearing—5064
Installer, Bushing—5066
Seal Protector—6992
Installer, Input Gear Bearing—7829-A
Installer, Seal—7884
Installer, Pump Housing Seal—7888
Installer, Bearing—8033-A
Installer, Boot Clamp—C-4975–A