JEEP CHEROKEE 1995 Service Repair Manual

(29) Align and position differential top case on bot-
tom case (Fig. 55). Align using scribe marks made at
disassembly.
(30) Install and tighten differential case bolts to
specified torque.
(31) Install first mainshaft bearing spacer on
mainshaft (Fig. 56).(32) Install bearing rollers on mainshaft (Fig. 56).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(33) Install remaining bearing spacer on mainshaft
(Fig. 56). Do not displace any bearings while install-
ing spacer.
(34) Install differential (Fig. 57).Do not displace
mainshaft bearings when installing differential.
(35) Install differential snap ring (Fig. 58).
Fig. 56 Installing Mainshaft Bearing Rollers and
Spacers
Fig. 55 Differential Case Assembly
Fig. 57 Differential Installation
Fig. 58 Installing Differential Snap Ring
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(36) Install intermediate clutch shaft (Fig. 59).
(37) Install clutch shaft thrust washer (Fig. 60).(38) Install clutch shaft snap ring (Fig. 61).
(39) Inspect mode fork assembly (Fig. 62). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 62). Replace
worn, damaged components.
Fig. 59 Installing Intermediate Clutch Shaft
Fig. 60 Installing Clutch Shaft Thrust Washer
Fig. 61 Installing Clutch Shaft Snap Ring
Fig. 62 Mode Fork Assembly Inspection
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(40) Install mode sleeve in mode fork (Fig. 63).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(41) Install mode fork and mainshaft assembly in
case (Fig. 64). Rotate mainshaft slightly to engage
shaft with low range gears.
(42) Rotate mode fork pin into shift sector slot.
(43) Install shift rail (Fig. 65).Be sure rail is
seated in both shift forks.
(44) Rotate shift sector to align lockpin hole in low
range fork with access hole in case.
(45) Insert an easy-out in range fork lockpin to
hold it securely for installation (Fig. 66).Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
Fig. 63 Installing Mode Fork And Sleeve
Fig. 64 Assembled Mainshaft And Mode Fork
Installation
Fig. 65 Shift Rail Installation
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(46) Insert lockpin through access hole and into
shift fork (Fig. 66). Then remove easy-out and seat
the pin with pin punch.
(47) Install plug in lockpin access hole.
(48) Install transfer case shift lever and attaching
nut. Tighten nut to 30 Nzm (22 ft. lbs.) torque.
(49) Install detent plunger, detent spring and de-
tent plug in case (Fig. 67).(50) Install front output shaft (Fig. 68).
(51) Install drive chain (Fig. 68). Engage chain
with front output shaft sprocket teeth.
(52) Install drive sprocket (Fig. 68).
(53) Engage drive sprocket teeth with chain. Then
engage sprocket splines with mainshaft splines.
(54) Install drive sprocket snap ring (Fig. 69).
Fig. 66 Installing Low Range Fork Lockpin
Fig. 67 Detent Pin, Spring And Plug Installation
Fig. 68 Drive Chain And Sprocket Installation
Fig. 69 Drive Sprocket Snap Ring Installation
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(55) Replace front output shaft rear bearing (Fig.
70). Remove bearing with internal puller and slide
hammer. Install new bearing with Tool Handle
C-4171 and Installer 5066. Lubricate bearing after
installation.
(56) Install new seal in oil pump feed housing with
Special Tool 7888 (Fig. 71).
(57) Install new pickup tube O-ring in oil pump
(Fig. 72).(58) Insert oil pickup tube in oil pump and attach
oil screen and connecter hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 73). Be sure screen is seated in case slot as
shown.
(59) Install magnet in front case pocket (Fig. 74).
(60) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of front case.
(61) Align and install rear case on front case. Be
sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
Fig. 70 Front Output Shaft Rear Bearing Installation
Fig. 71 Oil Pump Seal Installation
Fig. 72 Pickup Tube O-Ring Installation
Fig. 73 Oil Screen And Pickup Tube Installation
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(62) Install and tighten front case-to-rear case
bolts to 41 Nzm (30 ft. lbs.) torque.Be sure to in-
stall a washer under each bolt used at case
dowel locations.
(63) Tap rear retainer bearing out of retainer with
hammer and brass drift.
(64) Install bearing in rear retainer with Driver
Handle C-4171 and Installer 5064 (Fig. 75).
(65) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of rear retainer.
(66) Install locating dowel in rear retainer (if re-
moved) and install retainer on the case. Tighten re-
tainer bolts to 41 Nzm (30 ft. lbs.) torque.(67) Install new rear bearing snap ring (Fig. 76).
Lift mainshaft slightly to seat snap ring if necessary.
(68) Remove extension housing seal if not removed
previously.
(69) Replace extension housing bushing (Fig. 77).
²Use Tools C-4171 and 7889-A to remove bushing
²Use Tools C-4171 and 5066 to install bushing
Fig. 74 Installing Case Magnet
Fig. 75 Installing Rear Bearing In Retainer
Fig. 76 Rear Bearing Snap Ring Installation
JNP242 TRANSFER CASE 21 - 329

(70) Install new extension housing oil seal with Spe-
cial Tool 7891 (Fig. 78).
(71) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of extension housing.
(72) Install extension housing on case. Tighten
housing bolts to 41 Nzm (30 ft. lbs.) torque.(73) Install front yoke. Secure yoke with new seal
washer and nut. Tighten nut to 149 Nzm (110 ft. lbs.)
torque.
(74) Install new gasket on vacuum switch and in-
stall switch in case. Tighten switch to 27 Nzm (20 ft.
lbs.) torque.
(75) Install speedometer components.
(76) Install and tighten drain plug to 47 Nzm (35
ft. lbs.) torque.
(77) After installing transfer case, refill with rec-
ommended lubricant.
(78) Tighten fill plug to 47 Nzm (35 ft. lbs.) torque.
(79) Adjust transfer case shift linkage.
Fig. 77 Extension Housing Bushing Replacement
Fig. 78 Seating Extension Housing Seal
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NP242 TRANSFER CASE
JNP242 TRANSFER CASE 21 - 331

LEGEND FOR NP242 TRANSFER CASE
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TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TORQUE SPECIFICATIONSÐMANUAL
TRANSMISSION
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 333