JEEP XJ 1995 Service And Repair Manual

(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
21 - 330 NP242 TRANSFER CASEJ

NP242 TRANSFER CASE
JNP242 TRANSFER CASE 21 - 331

LEGEND FOR NP242 TRANSFER CASE
21 - 332 NP242 TRANSFER CASEJ

TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TORQUE SPECIFICATIONSÐMANUAL
TRANSMISSION
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 333

SELECTIVE SNAP RING CHARTÐAX 15 MANUAL TRANSMISSION
21 - 334 TRANSMISSION/TRANSFER CASE SPECIFICATIONSJ

30RH/32RH GENERAL SPECIFICATIONS
30RH/32RH SNAP RING/THRUST WASHER/THRUST PLATE SPECIFICATIONS
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 335

30RH/32RH PRESSURE TEST SPECIFICATIONS
30RH/32RH TORQUE SPECIFICATIONS
21 - 336 TRANSMISSION/TRANSFER CASE SPECIFICATIONSJ

AW-4 GENERAL SPECIFICATIONS
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 337

AW-4 OIL PUMP WEAR LIMITS
AW-4 CLUTCH DISC AND PLATE THICKNESS
21 - 338 TRANSMISSION/TRANSFER CASE SPECIFICATIONSJ