JEEP CHEROKEE 1988 Service Repair Manual

Fig. 2: Exploded View Of Transfer Case (Model 207)
Courtesy of Chrysler Corp.

Fig. 3: Exploded View Of Transfer Case (Model 231)
Courtesy of Chrysler Corp.
CLEANING & INSPECTION
Clean all parts with solvent. Dry with compressed air.
Replace all oil seals, "O" rings and snap rings. Check all parts for
wear or damage. Replace all worn or damaged parts. If low range
annulus gear inside front case is damaged or worn, front case and gear
must be replaced as an assembly. Replace oil pump as an assembly if
any part is damaged or worn.
TRANSFER CASE REASSEMBLY
NOTE: When installing bearings, ensure bearing bores are aligned
with oil feed holes.
1) Lubricate all parts with Dexron III before installing.

Install output shaft front bearing with NEW snap ring. Install output
shaft oil seal in front case. Install snap ring on NEW input gear
bearing. See Fig. 2 or 3.
2) Press input gear bearing so snap ring is seated against
case. Using press, install NEW input gear pilot bearing. Assemble low
range gear, input gear, thrust washers and retainer.
3) Install snap ring. Ensure snap ring is seated in low range
gear groove. Start input gear shaft into bearing in front case. Press
input shaft gear into bearing.
CAUTION: DO NOT press against end surfaces of gear. Failure to use
proper size tool could lead to gear case or thrust washer
damage.
4) Install input gear snap ring. Install oil seal in front
bearing retainer. Apply a 1/8" bead of silicone sealant to retainer
mating surface. Align oil channel in retainer with oil feed hole in
case. Install retainer on case. Tighten bolts to specification.
5) Install sector shaft "O" ring and bushing. Install range
sector in case. Install range lever and nut. Install detent, detent
spring and plug. Tighten to specification. See TORQUE SPECIFICATIONS.
Install NEW pads and fork rail bushings on range fork. Install range
fork and shift hub.
6) Ensure range fork pin is engaged with range sector slot.
Press front bearing in drive sprocket until bearing is flush with bore
edge. Install rear bearing until bearing is 3/16" below bore edge. See
Fig. 4 .
7) Install inserts and spring in synchronizer hub. Install
sprocket on mainshaft. Install synchronizer stop ring on mainshaft.
Ensure stop ring is seated. Install synchronizer hub on mainshaft.
Align and seat hub inserts on stop ring lugs. Install synchronizer hub
snap ring.
8) Install synchronizer sleeve on hub. Ensure sleeve is
positioned so beveled spline ends are facing stop ring. Ensure sleeve
tooth is aligned (centered) over each synchronizer strut. Gear clash
will occur if strut and sleeve teeth are misaligned. Install NEW pads
on mode fork. Engage mode fork in synchronizer sleeve. Install
mainshaft and fork assembly in case. Ensure mode fork shift rail is
seated in both range fork bushings.
9) Install output shaft and drive chain assembly. Install
mode spring on shift rail. Using bearing driver, install output shaft
rear bearing. Lubricate bearing after installation. Install seal in
oil pump feed housing. Install oil pump in housing. Tighten to
specification.
10) Install oil pick-up tube "O" ring in oil pump. Prime oil
pump by pouring ATF into pump through pick-up tube opening. Install
oil pump and pick-up tube in case. Ensure oil screen is properly
positioned. See Fig. 5. Install magnet in front case. Apply 1/8" bead
of silicone sealer to front case. Install rear case. Tighten to
specification. See TORQUE SPECIFICATIONS . Ensure mainshaft splines are
engaged with oil pump inner gear and a washer is used on bolts at
dowel locations.
11) Install rear bearings in retainer. Apply 1/8" bead of
silicone sealer and install retainer to case. Install rear retainer
snap ring. Install extension housing. Install front companion yoke.
Install NEW gasket on vacuum switch. Install vacuum switch in case.
Fill transfer case with Dexron III.

Fig. 4: Installing Drive Sprocket Bearings
Courtesy of Chrysler Corp.
Fig. 5: Identifying Oil Pump Screen Position
Courtesy of Chrysler Corp.

TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Companion Flange Nut
Chrysler Corp. ....................... 130-200 (176-271)
General Motors ................................ 80 (108)
Jeep ......................................... 110 (149)
Detent Plug
General Motors ................................. 11 (15)
Chrysler Corp. & Jeep .......................... 15 (20)
Drain & Fill Plug .......................... 30-40 (41-54)
Extension Housing Bolt ..................... 20-25 (27-34)
Front Bearing Retainer Bolt
Chrysler Corp. & Jeep .......................... 16 (22)
General Motors ................................. 14 (19)
Front Case-to-Rear Case Bolt
Chrysler Corp.
Flange Head Bolt ........................ 35-45 (47-61)
All Other Bolts ........................ 20-25 (27-34)
General Motors ................................. 23 (31)
Jeep ..................................... 20-25 (27-34)
Range Lever Nut ............................ 15-20 (20-27)
Rear Bearing Retainer Bolt ................. 20-25 (27-34)
Rear Crossmember ................................. 30 (41)
Shift Lever Lock Bolt ............................ 10 (14)
Speed Sensor Bolt ................................ 23 (31)
Transfer Case-to-Transmission Nut ................ 26 (35)
Vacuum Switch
Chrysler Corp. ........................... 15-25 (20-34)
General Motors ................................. 17 (23)
Jeep ..................................... 20-25 (27-34)
INCH Lbs.
Control Cable Lock Nut ............................ 18 (2)









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VACUUM DIAGRAMS
For vacuum diagrams, refer to appropriate VACUUM DIAGRAMS
article in the ENGINE PERFORMANCE section.

\003
TR AN SFE R C ASE - N P/N V 2 42

1988 J e ep C hero ke e
1987-96 TRANSFER CASES
Jeep - New Venture 242
Cherokee, Comanche, Wagoneer, Grand Wagoneer
IDENTIFICATION
Transfer case can be identified by an I.D. tag, located on
rear case. I.D. tag provides model number, serial number and low range
ratio. Date of manufacture is the serial number (I.D. number). This
information is necessary when ordering parts.
DESCRIPTION
Model 242 transfer case is a chain-driven, 2-piece aluminum
case, with full time operation. Torque input in 4WD high and low range
is undifferentiated.
ADJUSTMENTS
GEARSHIFT LINKAGE
Remove shift boot and shift to 4L position. Loosen trunnion
nut. Adjust trunnion and shift rod until rod fits freely. Tighten
trunnion nut and remove shim.
TROUBLE SHOOTING
SYMPTOM DIAGNOSIS
Will Not Shift Or Difficult To Shift Into Gear
Check fluid level. Check linkage adjustment. Ensure transfer
case external linkage is not binding. Internal parts may be worn or
damaged.
Noisy In All Gears
Check fluid level. Ensure correct fluid is used. If fluid is
okay, locate noise and check for possible internal mechanical problem.
Jumps Out Of Gear Or Noisy In 4WD
Transfer case not completely in gear; check shift linkage.
Range fork damaged. Inserts are worn. Shift fork binding on shift
rail. Low range gear worn or damaged.
Fluid Leaking From Vent Or Seals
Transfer case overfilled. Vent plugged. Output shaft seals
are damaged or not installed properly.
Transfer Case Will Not Shift Through High Lock Range
Incomplete shift due to driveline torque load; momentarily
release accelerator pedal to complete shift. Check tire pressure and
tire wear. Vehicle overloaded; remove load and check shifting.
ON-VEHICLE SERVICE
FRONT OIL SEAL

Removal & Installation
1) Mark front propeller shaft and flange for alignment
purposes. Remove front propeller shaft. Remove flange. Discard washer
and nut. Using a screwdriver, carefully remove oil seal. Ensure seal
contact surface is clean.
2) Apply ATF to seal lip and yoke seal surface. Install oil
seal and flange with new washer and nut. Install front propeller shaft
using alignment marks. Check transfer case fluid.
EXTENSION HOUSING OIL SEAL & BUSHING
NOTE: When replacing oil seal, DO NOT remove extension housing.
Removal & Installation
1) Mark rear propeller shaft and flange for installation
purposes. Remove rear propeller shaft. Remove bolts and tap extension
housing in a clockwise direction and remove extension housing. DO NOT
pry on extension housing. Using a screwdriver, remove oil seal from
extension housing.
2) Using bushing driver, replace bushing in extension
housing. Install new extension housing oil seal. Apply silicone
sealant to extension housing mating surface. Install extension
housing. Reverse removal procedure to complete installation.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal & Installation
1) Shift transfer case into Neutral position and drain fluid.
Mark front and rear drive shaft for installation purposes. Remove
front and rear drive shafts. Disconnect vacuum lines and speedometer
cable. Remove rear crossmember.
2) Disconnect shift linkage. Support transfer case with a
jack. Separate transfer case from transmission. Remove transfer case.
To install, reverse removal procedure. Tighten bolts to specification.
See TORQUE SPECIFICATIONS . Adjust shift linkage, if necessary.
TRANSFER CASE DISASSEMBLY
1) Remove drain and fill plugs. See Fig. 1. Remove front
companion flange, washer and seal. Place transfer case in 4L position.
Remove extension housing. See EXTENSION HOUSING OIL SEAL & BUSHING
under ON-VEHICLE SERVICE. Remove rear bearing snap ring. Remove rear
bearing retainer. Separate rear case from front case using prybars or
screwdriver. DO NOT damage mating surfaces.
NOTE: DO NOT disassemble oil pump, replace as unit only.
2) Remove oil pump, pick-up tube and screen from rear case.
Remove pick-up tube "O" ring from oil pump. Remove magnet from front
case. Remove drive sprocket snap ring. Remove drive sprocket and drive
chain.
3) Remove front output shaft. Remove shift lever from sector
shaft. Remove shift detent plug, spring and plunger. Remove plug from
low range fork lock pin access hole. Move shift sector until lock pin
is aligned with hole. Remove lock pin with No. 1 screw extractor.
4) Remove shift rail from fork assembly. Remove mode fork and
mainshaft as an assembly. Record mode sleeve position. Remove mode
shift sleeve and mode fork assembly. Remove sleeve from fork. Remove

intermediate clutch shaft snap ring from mainshaft.
5) Remove clutch shaft thrust ring. Remove intermediate
clutch shaft. Remove differential retaining snap ring. Remove
differential assembly. Remove differential needle bearings and thrust
washers from mainshaft. Remove low range fork and hub.
6) Remove shift sector. Remove shift sector bushing and "O"
ring. Remove front bearing retainer. Remove input gear snap ring.
Using a press, remove input and low range gear assembly from input
gear bearing. Remove low range gear snap ring.
7) Remove input gear retainer, thrust washers and input gear.
Mark differential halves for reassembly purposes. Separate
differential halves. Remove planetary gear and thrust washers.
8) Record mainshaft gear and sprocket gear position. Remove
gears. Remove front output shaft front bearing oil seal, snap ring and
front bearing. Using a press, remove input gear bearing.
9) Using slide hammer and internal puller, remove input gear
pilot bearing. Using slide hammer and internal puller, remove front
output shaft rear bearing.
Fig. 1: Exploded View Of Model 242 Transfer Case
Courtesy of Chrysler Motors.
CLEANING & INSPECTION

1) Clean all parts with solvent. Dry with compressed air.
Replace all oil seals, "O" rings and snap rings. Check all parts for
wear or damage. Replace all worn or damaged parts. Apply Dexron II to
all parts before installing.
2) Inspect low range annulus gear inside front case. If gear
is worn or damaged, replace case and gear as an assembly. Replace oil
pump as an assembly if any part is damaged or worn.
NOTE: When installing bearings, ensure bearing bores are aligned
with oil feed holes.
TRANSFER CASE REASSEMBLY
1) Install front output shaft front bearing, snap ring and
oil seal. Install snap ring on input gear bearing. Using a wooden
block and press, install input gear until snap ring is against case.
2) Install input gear pilot bearing. Assemble low range gear,
thrust washers, input gear and retainer. Install low range gear snap
ring. Ensure snap ring is seated properly in groove.
3) Start input gear shaft through the bearing in front case.
Using a press, install input gear shaft through bearing. Ensure
adapter is positioned properly before pressing shaft.
NOTE: Ensure proper size tool is used to press input gear shaft;
wrong size tool can damage case and thrust washers and will
move pilot bearing too far into gear bore.
4) Install input gear snap ring. Install front bearing
retainer oil seal. Apply 1/8" bead of silicone sealant to front
bearing retainer mating surface. Install front bearing retainer on
front case. Install sector shaft "O" ring and bushing. Install shift
sector.
5) Install detent pin, spring and plug. Install low range
fork pads. Assemble low range fork and hub. Ensure low range fork pin
is engaged in shift sector slot. Install differential sprocket gear in
lower differential case. Install planet gears and new thrust washers
on lower case pins.
6) Ensure thrust washers are positioned on top and bottom of
each planet gear. Install mainshaft gear. Align marks on upper and
lower differential case. Install bolts and tighten to specifications.
See TORQUE SPECIFICATIONS . Install needle bearing spacer on mainshaft.
7) Using petroleum jelly to hold needles, install bearings on
mainshaft. Install other spacer. Install differential assembly. Ensure
all needle bearings are in place. Install differential snap ring.
Install intermediate clutch shaft. Install thrust washer and snap
ring. Install mode shift sleeve in mode fork.
8) Install mode fork assembly on mainshaft. Ensure mode shift
sleeve splines engage with differential splines. Install mode fork and
mainshaft assembly in case. If necessary, rotate mainshaft slightly to
engage mainshaft with low range components.
9) Install mode fork pin into shift sector slot. Install
shift rail. Ensure shift rail is seated in shift forks. Rotate shift
sector so lock pin can be installed. Install lock pin so tapered end
is in fork and rail. Install plug. Install shift lever and nut on
shift sector shaft.
10) Install detent plunger, spring and plug. Install front
output shaft. Install drive chain and sprocket. Install drive sprocket
snap ring. Install front output shaft rear bearing.
11) Install oil seal in oil pump housing. Assemble oil pump
gears in housing. Ensure oil feed hole is aligned with hole in
housing. Install oil pump screws. Tighten to specification. Install

"O" ring in oil pump. Install oil pick-up tube and screen. Ensure
screen is properly positioned. See Fig. 2.
12) Install magnet in front case. Apply 1/8" bead of silicone
sealant to front case mating surface. Assemble case halves together.
Tighten to specification. Ensure mainshaft splines are engaged with
oil pump inner gear and a washer is used on bolts at dowel locations.
13) Install rear retainer bearing in retainer. Apply 1/8"
bead of silicone sealer and install retainer to case. Install rear
bearing snap ring. Install extension housing. Install front companion
flange. Install vacuum switch and drain plug. Fill transfer case with
Dexron II.
Fig. 2: Identifying Oil Pump Screen Position
Courtesy of Chrysler Motors.
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS TABLE








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Application Ft. Lbs. (N.m)
Companion Flange Nut .................... 90-130 (122-176)
Detent Plug ...................................... 14 (19)
Drain & Fill Plug ................................ 27 (37)
Extension Housing Bolt ........................... 26 (35)
Front Bearing Retainer Bolt ...................... 12 (16)
Front Case-to-Rear Case Bolt ............... 26-34 (35-46)
Shift Fork Set Screw ............................. 15 (20)
Transfer Case-to-Transmission .................... 26 (35)









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