JEEP CHEROKEE 1995 Service Repair Manual

(26) Remove shift rail by pulling it straight up and
out of fork (Fig. 15).
(27) Remove mode fork and mainshaft as assembly
(Fig. 16).
(28) Remove mode shift sleeve and mode fork as-
sembly from mainshaft (Fig. 17). Note position of
mode sleeve in fork and remove sleeve.
(29) Remove intermediate clutch shaft snap ring
(Fig. 18).
Fig. 15 Shift Rail Removal
Fig. 16 Mode Fork And Mainshaft Removal
Fig. 17 Mode Fork And Sleeve Removal
Fig. 18 Intermediate Clutch Shaft Snap Ring
Removal
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(30) Remove clutch shaft thrust ring (Fig. 19).
(31) Remove intermediate clutch shaft (Fig. 20).(32) Remove differential snap ring (Fig. 21).
(33) Remove differential (Fig. 22).
(34) Remove differential needle bearings and both
needle bearing thrust washers from mainshaft.
Fig. 19 Clutch Shaft Thrust Ring Removal
Fig. 20 Intermediate Clutch Shaft Removal
Fig. 21 Differential Snap Ring Removal
Fig. 22 Differential Removal
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(35) Slide low range fork pin out of shift sector slot
(Fig. 23)
(36) Remove low range fork and hub (Fig. 24).(37) Remove shift sector (Fig. 25).
(38) Remove shift sector bushing and O-ring (Fig.
26).
Fig. 23 Disengaging Low Range Fork
Fig. 24 Low Range Fork And Hub Removal
Fig. 25 Shift Sector Position
Fig. 26 Sector Bushing And O-Ring Removal
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(39) Remove front bearing retainer bolts.
(40) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 27). Position
screwdriver in slots cast into retainer.
(41) Remove input gear snap ring (Fig. 28).(42) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 29).
(43) Remove low range gear snap ring (Fig. 30).
Fig. 27 Front Bearing Retainer Removal
Fig. 28 Input Gear Snap Ring Removal
Fig. 29 Input And Low Range Gear Assembly
Removal
Fig. 30 Low Range Gear Snap Ring Removal/
Installation
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(44) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 31).
(45) Inspect low range annulus gear (Fig. 32).
Gear is not a serviceable component. If dam-
aged, replace gear and front case as assembly.
(46) Remove oil seals from following components:
²rear retainer
²extension housing
²oil pump
²case halves
(47) Mark differential case halves for reference.
(48) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 33).
(49) Remove thrust washers and planet gears from
case pins (Fig. 34).(50) Remove mainshaft and sprocket gears from
bottom case (Fig. 35). Note gear position for reference
before separating them.
OVERHAUL CLEANING AND INSPECTION
Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
case and retainer seal surfaces.
Clean the oil pickup screen with solvent and allow
it to air dry. Use compressed air to remove solvent
residue from all oil feed passages and channels in
case halves.
Fig. 31 Low Range Gear Disassembly
Fig. 32 Inspecting Low Range Annulus Gear
Fig. 33 Separating Differential Case Halves
Fig. 34 Planet Gears And Thrust Washer Removal
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Inspect the differential gears, thrust washers and
case halves. Replace the mainshaft gear if the gear
teeth or the brass ring on the underside of the gear
are damaged. Replace the differential as an assembly
if the gears, case halves, or the pins in the lower case
half are damaged.
Inspect the case halves, extension housing and re-
tainers for cracks, porosity, or damaged sealing sur-
faces. Inspect the shafts, gears, chain and shift
components for wear or damage.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam-
aged bearings as outlined in the assembly section.
TRANSFER CASE ASSEMBLY
(1) Lubricate transfer case components with auto-
matic transmission fluid or petroleum jelly (where in-
dicated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Be sure re-
placement bearings do not block these feed holes.
(2) Remove snap ring that retains front output
shaft front bearing in case (Fig. 36). Then remove
bearing. Use hammer handle, or hammer and brass
punch to tap bearing out of case.
(3) Install new front output shaft bearing with Tool
Handle C-4171 and Installer 8033A (Fig. 37).
(4) Install front bearing snap ring (Fig. 36).
(5) Install new front output shaft oil seal as fol-
lows:(a) Tap seal into bore until flush with upper edge
of case bore. Use suitable size installer tool to start
seal into place (Fig. 38).
(b) Seat seal 2.03 to 2.5 mm (0.080 to 0.100 in.)
belowtop edge of seal bore in front case (Fig. 39).
This is correct final seal position. Use suitable size
installer tool or blunt punch to final-seat seal.
Check seal depth with a dial caliper or depth mi-
crometer.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown (Fig.
39). The seal could work loose if not seated to the
recommended depth.
(6) Remove input gear bearing with Tool Handle
C-4171 and Remover C-4210 (Fig. 40).
Fig. 35 Mainshaft And Sprocket Gear RemovalFig. 36 Front Output Shaft Front Bearing Snap Ring
Removal
Fig. 37 Front Output Shaft Front Bearing Installation
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(7) Install snap ring on new input gear bearing.
(8) Install new input gear bearing with shop press
and wood block. Install bearing far enough to seat
snap ring against case (Fig. 41).
(9) Remove input gear pilot bearing with slide
hammer and internal puller (Fig. 42).
Fig. 38 Starting Front Output Shaft Seal Into Case
Bore
Fig. 39 Front Output Seal Installation Depth
Fig. 40 Input Gear Bearing Removal
Fig. 41 Seating Input Gear Bearing
Fig. 42 Input Gear Pilot Bearing Removal
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(10) Install new pilot bearing with Tool Handle
C-4171 and Installer 5065 (Fig. 43).
(11) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 44).
(12) Install low range gear snap ring (Fig. 45).
(13) Lubricate input gear and low range gears with
automatic transmission fluid.
(14) Start input gear shaft into front case bearing.
(15) Press input gear shaft into front bearing.CAUTION: Be sure the input gear installer tool is
the proper size. The wrong size tool could push the
input gear pilot bearing too far into the gear bore
(Fig. 46). Also, do not press against the end sur-
faces of the low range gear. The gear case and
thrust washers could be damaged.
Fig. 43 Input Gear Pilot Bearing Installation
Fig. 44 Low Range And Input Gear Assembly
Fig. 45 Install Low Range Gear Snap Ring
Fig. 46 Input Gear Installation
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(16) Install new input gear snap ring (Fig. 47).
(17) Install new seal in front bearing retainer with
Tool Handle C-4171 and Installer 7884 (Fig. 48).(18) Apply 3 mm (1/8 in.) wide bead of Mopar gasket
maker. silicone adhesive sealer, or Loctite 518 to seal
surface of front bearing retainer.
(19) Install front bearing retainer (Fig. 49).
Tighten retainer bolts to 16 ft. lbs. (21 Nzm) torque.
(20) Install new sector shaft O-ring and bushing
(Fig. 50).
(21) Install shift sector.
Fig. 47 Input Gear Snap Ring Installation
Fig. 48 Front Bearing Retainer Seal Installation
Fig. 49 Installing Front Bearing Retainer
Fig. 50 Sector O-Ring And Bushing Installation
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(22) Install new pads in low range fork (Fig. 51).
(23) Assemble low range fork and hub (Fig. 51).
(24) Position low range fork and hub in case. Be
sure low range fork pin is engaged in shift sector slot
(Fig. 52).
(25) Lubricate differential components with auto-
matic transmission fluid.(26) Install sprocket gear in differential bottom case
(Fig. 53).
(27) Install differential planet gears and new
thrust washers (Fig. 54).Be sure thrust washers
are installed at top and bottom of each planet
gear.
(28) Install differential mainshaft gear (Fig. 54).
Fig. 51 Assembling Low Range Fork And Hub
Fig. 52 Positioning Low Range Fork
Fig. 53 Installing Differential Sprocket Gear
Fig. 54 Installing Mainshaft And Planet Gears
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