front diff JEEP CHEROKEE 1988 Service Owner's Guide
[x] Cancel search | Manufacturer: JEEP, Model Year: 1988, Model line: CHEROKEE, Model: JEEP CHEROKEE 1988Pages: 1378, PDF Size: 19.9 MB
Page 994 of 1378
1984-86 (904 HD)
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.0 Qts. (7.6L) \
1987-88
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.5 Qts. (8.0L) \
Cooling System (
2)
4-Cylinder .................................. 10.0 Qts. (9.5L)
6-Cylinder ................................. 12.0 Qts. (11.4L)
Engine Oil
4-Cylinder ................................... 4.0 Qts. (3.8L)
6-Cylinder ................................... 6.0 Qts. (5.7L)
Fuel Tank
Standard .................................. 13.5 Gals. (51.1L)
Optional .................................... 20 Gals. (75.7L)
Manual Transmission (
3)
AX4 (AISIN) .................................. 7.4 Pts. (3.5L) \
T4 (Borg-Warner) ............................. 3.9 Pts. (1.8L) \
AX5 (AISIN) .................................. 7.0 Pts. (3.3L) \
T5 (Borg-Warner) ............................. 4.5 Pts. (2.1L) \
Transfer Case
1985-86
Selec-Trac (229 Full-Time) ................. 6.0 Pts. (2.8L) \
Command-Trac (Part-Time 207) ............... 4.5 Pts. (2.1L) \
1987
Selec-Trac ................................. 2.5 Pts. (1.2L)
Command-Trac ............................... 2.2 Pts. (1.0L)
1988
Selec-Trac ................................. 3.0 Pts. (1.4L)
Command-Trac ............................... 2.2 Pts. (1.0L)
Drive Axles (
3)
Front ........................................ 2.5 Pts. (1.2L)
Front (Disconnect Housing) .................. 5.0 Ozs. (0.15L) \
Rear ......................................... 2.5 Pts. (1.2L)
Rear (Trac-Lok) (
4) .......................... 2.5 Pts. (1.2L)
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(
2) - Includes 2.3 qts. for coolant recovery bottle.
(
3) - Fill to bottom of filler plug hole.
(
4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
\
\
\
\
\
\
\
\f
105,000 MILE (168,000 KM) SERVICE
105,000 MILE (168,000 KM) SERVICE \
\
\
\
\
\
\
Service Or Inspect
\
\
\
\
\
\
\
Verify Last Major Service Was Performed
\b\
\
\
\
\
\
\
Check Fluid Levels
\b\
\
\
\
\
\
\
Check Fuel Lines, Connections
\b\
\
\
\
\
\
\
Check Cooling System Hoses and Clamps
\b\
\
\
\
\
\
\
Check Coolant Strength
\b\
\
\
\
\
\
\
Check Exhaust System & Heat Shielding
\b\
\
\
\
\
\
\
Page 997 of 1378
1988
Selec-Trac ................................. 3.0 Pts. (1.4L)
Command-Trac ............................... 2.2 Pts. (1.0L)
Drive Axles (
3)
Front ........................................ 2.5 Pts. (1.2L)
Front (Disconnect Housing) .................. 5.0 Ozs. (0.15L) \
Rear ......................................... 2.5 Pts. (1.2L)
Rear (Trac-Lok) (
4) .......................... 2.5 Pts. (1.2L)
(
1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(
2) - Includes 2.3 qts. for coolant recovery bottle.
(
3) - Fill to bottom of filler plug hole.
(
4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
\
\
\
\
\
\
\
\f
112,500 MILE (180,000 KM) SERVICE
112,500 MILE (180,000 KM) SERVICE \
\
\
\
\
\
\
Service Or Inspect
\
\
\
\
\
\
\
Verify Last Major Service Was Performed
\b\
\
\
\
\
\
\
Check Fluid Levels
\b\
\
\
\
\
\
\
Check Cooling System Hoses and Clamps
\b\
\
\
\
\
\
\
Check Coolant Strength
\b\
\
\
\
\
\
\
Clean Battery and Battery Terminals
\b\
\
\
\
\
\
\
Check Exhaust System & Heat Shielding
\b\
\
\
\
\
\
\
Check Operation of Horn, Wipers/Washers & All Exterior Lights
\b\
\
\
\
\
\
\
Inspect Condition of Wiper Blades
\b\
\
\
\
\
\
\
Check Headlight Alignment
\b\
\
\
\
\
\
\
Check Seat Belt Webbing and Release Mechanisms
\b\
\
\
\
\
\
\
Check Parking Brake Operation
\b\
\
\
\
\
\
\
Check Shift/Clutch Interlock Operation
\b\
\
\
\
\
\
\
Inspect C/V Joint boots (4WD)
\b\
\
\
\
\
\
\
Inspect Underside of Vehicle (Bolts & Threaded Fasteners)
\b\
\
\
\
\
\
\
Check/Lube Manual Steering Gear
\b\
\
\
\
\
\
\
Check Drive Shaft Seals
\b\
\
\
\
\
\
\
Lubricate Ball Joints, Steering Linkage & Suspension
\b\
\
\
\
\
\
\
Lube Drive Shaft U-Joints and Slip Splines
\b\
\
\
\
\
\
\
Lube Front Axle Drive Joint and Pivot Bearings (4WD)
\b\
\
\
\
\
\
\
Lube Parking Brake Ratio Lever Pivot
Page 999 of 1378
Transfer Case ................................... Dexron-IIE ATF
Brake Caliper Bushings ........ GE 661 or DOW 111 Silicone Grease
Caliper Slide Pins ........... GE 661 or DOW 111 Silicone Grease
Wheel Bearings .................. Multi-Purpose NLGI Grade GC-LB
Drive Shaft U-Joints .............. Multi-Purpose NLGI Grade 2EP
Steering Linkage (
4)( 5) .................... NLGI Grade 2, GC-LB
Ball Joints (
4)( 6) ......................... NLGI Grade 2, GC-LB
Weatherstrip .......................... Silicone Spray Lubricant
Wheel Lug Nut Torque ...................... 95 ft. lbs. (129 N.m)
(
1) - SAE 10W-30 SH/CD is preferred.
(
2) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive when changing fluid.
(
3) - For vehicles operating under heavy-duty towing conditions,
use SAE 75W-140 Synthetic lube.
NOTE: Before using SAE 75W-140 Synthetic the old fluid must
be DRAINED and FLUSHED with clean mineral based axle
lubricant. Then refill with new synthetic lube.
(
4) - Use low pressure grease gun to prevent seal damage.
(
5) - Fill until lubricant squeezes out from the base of seals.
(
6) - Fill ball joint until seal starts to swell.
\
\
\
\
\
\
\
Fluid Capacities
\
\
\
\
\
\
\
Application ( 1) Quantity
Automatic Transmission
1984-86 (904 HD)
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.0 Qts. (7.6L) \
1987-88
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.5 Qts. (8.0L) \
Cooling System (
2)
4-Cylinder .................................. 10.0 Qts. (9.5L)
6-Cylinder ................................. 12.0 Qts. (11.4L)
Engine Oil
4-Cylinder ................................... 4.0 Qts. (3.8L)
6-Cylinder ................................... 6.0 Qts. (5.7L)
Fuel Tank
Standard .................................. 13.5 Gals. (51.1L)
Optional .................................... 20 Gals. (75.7L)
Manual Transmission (
3)
AX4 (AISIN) .................................. 7.4 Pts. (3.5L) \
T4 (Borg-Warner) ............................. 3.9 Pts. (1.8L) \
AX5 (AISIN) .................................. 7.0 Pts. (3.3L) \
T5 (Borg-Warner) ............................. 4.5 Pts. (2.1L) \
Transfer Case
1985-86
Selec-Trac (229 Full-Time) ................. 6.0 Pts. (2.8L) \
Command-Trac (Part-Time 207) ............... 4.5 Pts. (2.1L) \
1987
Selec-Trac ................................. 2.5 Pts. (1.2L)
Command-Trac ............................... 2.2 Pts. (1.0L)
1988
Selec-Trac ................................. 3.0 Pts. (1.4L)
Command-Trac ............................... 2.2 Pts. (1.0L)
Drive Axles (
3)
Front ........................................ 2.5 Pts. (1.2L)
Front (Disconnect Housing) .................. 5.0 Ozs. (0.15L) \
Rear ......................................... 2.5 Pts. (1.2L)
Rear (Trac-Lok) (
4) .......................... 2.5 Pts. (1.2L)
Page 1000 of 1378
(1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
(
2) - Includes 2.3 qts. for coolant recovery bottle.
(
3) - Fill to bottom of filler plug hole.
(
4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
\
\
\
\
\
\
\
\f
120,000 MILE (192,000 KM) SERVICE
120,000 MILE (192,000 KM) SERVICE \
\
\
\
\
\
\
Service Or Inspect
\
\
\
\
\
\
\
Verify Last Major Service Was Performed
\b\
\
\
\
\
\
\
Check Fluid Levels
\b\
\
\
\
\
\
\
Check Cooling System Hoses and Clamps
\b\
\
\
\
\
\
\
Check Coolant Strength
\b\
\
\
\
\
\
\
Check Accessory Drive Belts
\b\
\
\
\
\
\
\
Check Exhaust System & Heat Shielding
\b\
\
\
\
\
\
\
Clean Battery and Battery Terminals
\b\
\
\
\
\
\
\
Adjust Drive Belt Tension
\b\
\
\
\
\
\
\
Accessory Drive Belts
\b\
\
\
\
\
\
\
Adjust Idle - Propane Method (1987-88)
\b\
\
\
\
\
\
\
Ignition Timing
\b\
\
\
\
\
\
\
Lubricate Manifold Heat Control Valve (3.9L & 5.2L Engines)
\b\
\
\
\
\
\
\
Clean PCV Breather (3.9L & 5.2L Engines)
\b\
\
\
\
\
\
\
Clean EGR Passages (if equipped)
\b\
\
\
\
\
\
\
Inspect C/V Joint boots (4WD)
\b\
\
\
\
\
\
\
Inspect Underside of Vehicle (Bolts & Threaded Fasteners)
\b\
\
\
\
\
\
\
Check/Lube Manual Steering Gear
\b\
\
\
\
\
\
\
Check Drive Shaft Seals
\b\
\
\
\
\
\
\
Lubricate Ball Joints, Steering Linkage & Suspension
\b\
\
\
\
\
\
\
Lube Drive Shaft U-Joints and Slip Splines
\b\
\
\
\
\
\
\
Lube Front Axle Drive Joint and Pivot Bearings (4WD)
\b\
\
\
\
\
\
\
Inspect Front Wheel Bearings (4WD)
\b\
\
\
\
\
\
\
Clean and Lubricate Crankcase Inlet Air Cleaner
\b\
\
\
\
\
\
\
Suspension Bushings, Springs, Arms & Rear Jounce Bumpers
\b\
\
\
\
\
\
\
Page 1002 of 1378
Door & Hood Hinges ............................ Light Engine Oil
Manual Steering Box ............... Multi-Purpose NLGI Grade 2EP
Power Steering Pump ....................... Power Steering Fluid
Transfer Case ................................... Dexron-IIE ATF
Brake Caliper Bushings ........ GE 661 or DOW 111 Silicone Grease
Caliper Slide Pins ........... GE 661 or DOW 111 Silicone Grease
Wheel Bearings .................. Multi-Purpose NLGI Grade GC-LB
Drive Shaft U-Joints .............. Multi-Purpose NLGI Grade 2EP
Steering Linkage (
4)( 5) .................... NLGI Grade 2, GC-LB
Ball Joints (
4)( 6) ......................... NLGI Grade 2, GC-LB
Weatherstrip .......................... Silicone Spray Lubricant
Wheel Lug Nut Torque ...................... 95 ft. lbs. (129 N.m)
(
1) - SAE 10W-30 SH/CD is preferred.
(
2) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive when changing fluid.
(
3) - For vehicles operating under heavy-duty towing conditions,
use SAE 75W-140 Synthetic lube.
NOTE: Before using SAE 75W-140 Synthetic the old fluid must
be DRAINED and FLUSHED with clean mineral based axle
lubricant. Then refill with new synthetic lube.
(
4) - Use low pressure grease gun to prevent seal damage.
(
5) - Fill until lubricant squeezes out from the base of seals.
(
6) - Fill ball joint until seal starts to swell.
\
\
\
\
\
\
\
Fluid Capacities
\
\
\
\
\
\
\
Application ( 1) Quantity
Automatic Transmission
1984-86 (904 HD)
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.0 Qts. (7.6L) \
1987-88
Fluid Change ............................... 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ........................ 8.5 Qts. (8.0L) \
Cooling System (
2)
4-Cylinder .................................. 10.0 Qts. (9.5L)
6-Cylinder ................................. 12.0 Qts. (11.4L)
Engine Oil
4-Cylinder ................................... 4.0 Qts. (3.8L)
6-Cylinder ................................... 6.0 Qts. (5.7L)
Fuel Tank
Standard .................................. 13.5 Gals. (51.1L)
Optional .................................... 20 Gals. (75.7L)
Manual Transmission (
3)
AX4 (AISIN) .................................. 7.4 Pts. (3.5L) \
T4 (Borg-Warner) ............................. 3.9 Pts. (1.8L) \
AX5 (AISIN) .................................. 7.0 Pts. (3.3L) \
T5 (Borg-Warner) ............................. 4.5 Pts. (2.1L) \
Transfer Case
1985-86
Selec-Trac (229 Full-Time) ................. 6.0 Pts. (2.8L) \
Command-Trac (Part-Time 207) ............... 4.5 Pts. (2.1L) \
1987
Selec-Trac ................................. 2.5 Pts. (1.2L)
Command-Trac ............................... 2.2 Pts. (1.0L)
1988
Selec-Trac ................................. 3.0 Pts. (1.4L)
Command-Trac ............................... 2.2 Pts. (1.0L)
Drive Axles (
3)
Front ........................................ 2.5 Pts. (1.2L)
Front (Disconnect Housing) .................. 5.0 Ozs. (0.15L) \
Page 1004 of 1378
DRAINED and FLUSHED with clean mineral based (non-synthetic)
axle lubricant. Then refill with new synthetic lube.
(4) - Use low pressure grease gun to prevent seal damage.
( 5) - Fill until lubricant squeezes out from the base of seals.
( 6) - Fill ball joint until seal starts to swell.
\
\
\
\
\
\
\
FLUID CAPACITIES
FLUID CAPACITIES TABLE\
\
\
\
\
\
\
Application Quantity ( 1)
A/C System R-12 Refrigerant Capacity ............... 36-40 Ozs.
Automatic Transmission
1984-86 (904 HD)
Fluid Change .............................. 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ....................... 8.0 Qts. (7.6L)
1987-88
Fluid Change .............................. 4.0 Qts. (3.8L)
Overhaul (Dry Fill) ....................... 8.5 Qts. (8.0L)
Cooling System ( 2)
4-Cylinder ................................. 10.0 Qts. (9.5L)
6-Cylinder ................................ 12.0 Qts. (11.4L)
Engine Oil
4-Cylinder .................................. 4.0 Qts. (3.8L)
6-Cylinder .................................. 6.0 Qts. (5.7L)
Fuel Tank
Standard ................................. 13.5 Gals. (51.1L)
Optional ................................... 20 Gals. (75.7L)
Manual Transmission ( 3)
AX4 (AISIN) ................................. 7.4 Pts. (3.5L)
T4 (Borg-Warner) ............................ 3.9 Pts. (1.8L)
AX5 (AISIN) ................................. 7.0 Pts. (3.3L)
T5 (Borg-Warner) ............................ 4.5 Pts. (2.1L)
Transfer Case
1985-86
Selec-Trac (229 Full-Time) ................ 6.0 Pts. (2.8L)
Command-Trac (Part-Time 207) .............. 4.5 Pts. (2.1L)
1987
Selec-Trac ................................ 2.5 Pts. (1.2L)
Command-Trac .............................. 2.2 Pts. (1.0L)
1988
Selec-Trac ................................ 3.0 Pts. (1.4L)
Command-Trac .............................. 2.2 Pts. (1.0L)
Drive Axles ( 3)
Front ....................................... 2.5 Pts. (1.2L)
Front (Disconnect Housing) ................. 5.0 Ozs. (0.15L)
Rear ........................................ 2.5 Pts. (1.2L)
Rear (Trac-Lok) ( 4) ......................... 2.5 Pts. (1.2L)
( 1) - Capacities are recommended or calculated levels. Always use
dipstick (if available) to measure level.
( 2) - Includes 2.3 qts. for coolant recovery bottle.
( 3) - Fill to bottom of filler plug hole.
( 4) - Add 4 ozs. (118 ml) of Limited-Slip differential lubricant
additive first, then add new fluid.
\
\
\
\
\
\
\
Page 1116 of 1378
Condition Code Procedure
Air pressure incorrect .. B .................. Require repair
Bead broken ............. A ............ Require replacement.
Bead leaking, caused
by tire ................ A .. Require repair or replacement.
Bead wire/cord exposed .. A ............ Require replacement.
Cord or belt material
exposed ................ A ............ Require replacement.
Cord ply separations .... A ............ Require replacement.
Directional/asymmetrical
tires mounted
incorrectly ............ B ....... Require remounting and/or
repositioning.
Irregular tread wear,
affecting performance .. 2 ........ (1) Suggest replacement.
Load ratings less
than OEM
specifications ......... B ............ Require replacement.
Mixed tread types (all
season, performance, mud
and snow) on same axle . A ............ Require replacement.
Number of punctures
exceeds manufacturer's
limit .................. B ............ Require replacement.
Out of balance .......... B . Require rebalance of tire/wheel
assembly.
Ply separation .......... A ............ Require replacement.
Pull or lead, caused
by tire ................ A .. Require repair or replacement.
Radial and bias or
bias-belted ply tires
on same axle ........... B .. Require repair or replacement.
Radials are on the front
and not on the rear .... B ........... ( 2) Require repair or
replacement.
Run flat damage ......... A ............ Require replacement.
Shoulder cut ............ A ............ Require replacement.
Shoulder puncture ....... A ............ Require replacement.
Shoulder with plug ...... A ............ Require replacement.
Sidewall bulge .......... A ............ Require replacement.
Sidewall cut ............ A ............ Require replacement.
Sidewall indentation .... .. ......... No service required or
suggested.
Sidewall puncture ....... A ............ Require replacement.
Sidewall with plug ...... A ............ Require replacement.
Speed rating
designations
different
on same axle ........... 2 .. Suggest repair or replacement.
Tire and wheel assembly
has excessive run-out .. B ........... ( 3) Require repair or
replacement of appropriate
part.
Tires with more than
1/4" diameter difference
on a four-wheel drive
vehicle ................ B ............ Require replacement.
Tread area puncture larger
in diameter than
manufacturer's
specifications ......... B ............ Require replacement.
Tread missing pieces
Page 1177 of 1378
Condition Code Procedure
Air pressure incorrect .. B .................. Require repair
Bead broken ............. A ............ Require replacement.
Bead leaking, caused
by tire ................ A .. Require repair or replacement.
Bead wire/cord exposed .. A ............ Require replacement.
Cord or belt material
exposed ................ A ............ Require replacement.
Cord ply separations .... A ............ Require replacement.
Directional/asymmetrical
tires mounted
incorrectly ............ B ....... Require remounting and/or
repositioning.
Irregular tread wear,
affecting performance .. 2 ........ (1) Suggest replacement.
Load ratings less
than OEM
specifications ......... B ............ Require replacement.
Mixed tread types (all
season, performance, mud
and snow) on same axle . A ............ Require replacement.
Number of punctures
exceeds manufacturer's
limit .................. B ............ Require replacement.
Out of balance .......... B . Require rebalance of tire/wheel
assembly.
Ply separation .......... A ............ Require replacement.
Pull or lead, caused
by tire ................ A .. Require repair or replacement.
Radial and bias or
bias-belted ply tires
on same axle ........... B .. Require repair or replacement.
Radials are on the front
and not on the rear .... B ........... ( 2) Require repair or
replacement.
Run flat damage ......... A ............ Require replacement.
Shoulder cut ............ A ............ Require replacement.
Shoulder puncture ....... A ............ Require replacement.
Shoulder with plug ...... A ............ Require replacement.
Sidewall bulge .......... A ............ Require replacement.
Sidewall cut ............ A ............ Require replacement.
Sidewall indentation .... .. ......... No service required or
suggested.
Sidewall puncture ....... A ............ Require replacement.
Sidewall with plug ...... A ............ Require replacement.
Speed rating
designations
different
on same axle ........... 2 .. Suggest repair or replacement.
Tire and wheel assembly
has excessive run-out .. B ........... ( 3) Require repair or
replacement of appropriate
part.
Tires with more than
1/4" diameter difference
on a four-wheel drive
vehicle ................ B ............ Require replacement.
Tread area puncture larger
in diameter than
manufacturer's
specifications ......... B ............ Require replacement.
Tread missing pieces
Page 1197 of 1378
\003
TR AN SFE R C ASE - O VER HAU L ( 2 07/2 31)
1 988 J e ep C hero ke e
1983-96 TRANSFER CASES
Chrysler Corp., GM Corp., Jeep - New Process 207 & 231
Dodge; B1500 & Dakota
GMC/Chevrolet; "T" Series (Blazer & Jimmy)
Jeep; Cherokee, Comanche, Grand Cherokee, Wagoneer, Wrangler
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 231 transfer case is a part time, chain-driven, 4-
position unit with 2-piece aluminum case. Torque input in 4WD high and
low range is undifferentiated. 2WD operation is achieved by a vacuum
shift motor. Shift motor disconnects right front axle when 2WD is
selected. Vacuum shift motor is controlled by a vacuum switch located
on front of transfer case and actuated by shift sector.
ADJUSTMENTS
GEARSHIFT LINKAGE
Chrysler Corp.
Shift transfer case to 2H position. Raise and support
vehicle. Loosen lock bolt at trunnion. Ensure linkage rod slides
freely in trunnion. Verify transfer case range lever is fully engaged
in 2H position. Tighten lock bolt at trunnion. Lower vehicle. Check
shift linkage operation. Ensure transfer case shifts into and operates
properly in all gear ranges.
General Motors
Remove shift lever knob retainer. Remove shift lever knob.
Remove floor console. Place shift lever in Neutral. Pry control cable
end from shift lever. Loosen control cable lock nut. Check transfer
case to ensure it is in Neutral. Ensure shift lever is in Neutral.
Turn shift lever end of cable in or out as needed until it is aligned
with shift lever. Install control cable on shift lever. Tighten
control cable lock nut.
Jeep
Shift transfer case to 4L position. Raise and support
vehicle. Loosen lock bolt at trunnion. Ensure linkage rod slides
freely in trunnion. Verify transfer case range lever is fully engaged
in 4L position. Tighten lock bolt at trunnion. Lower vehicle. Check
shift linkage operation. Ensure transfer case shifts into and operates
properly in all gear ranges.
TESTING
VACUUM SWITCH
Shift to 2WD position. Locate vacuum switch on front of
Page 1199 of 1378
Will Not Shift Or Difficult To Shift Into Gear
Vehicle speed too high; slow vehicle to 2-3 MPH to shift.
Vehicle operated too long on dry paved surface; stop vehicle and place
in Reverse or Neutral to relieve driveline torque. Ensure transfer
case external linkage is not binding. Ensure correct fluid is used.
Internal parts may be worn or damaged.
Noisy In All Gears
Check fluid level. Ensure correct fluid is used. If fluid is
okay, locate possible internal mechanical problem.
Jumps Out Of Gear Or Noisy In 4WD
Transfer case not completely in gear; check shift linkage.
Range fork damaged. Shift fork pads are worn or shift fork binding.
Low range gear worn.
Fluid Leaking From Vent Or Seals
Transfer case overfilled. Vent plugged. Output shaft seals
are damaged or not installed properly.
ON-VEHICLE SERVICE
FRONT OIL SEAL
Removal & Installation
1) Mark front drive shaft and flange for installation
alignment reference. Remove front drive 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 flange seal surface. Install NEW
oil seal. Install flange and NEW washer and nut. Tighten nut to
specifications. See TORQUE SPECIFICATIONS . Install front drive shaft
using alignment marks. Check transfer case fluid.
EXTENSION HOUSING OIL SEAL & BUSHING
Removal & Installation
1) Mark rear drive shaft and flange for installation
alignment reference. Remove rear drive shaft. 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. To complete installation, reverse removal procedure.
REMOVAL & INSTALLATION
TRANSFER CASE
Removal
1) Shift transfer case into 4H and disconnect battery
negative cable. Raise vehicle, remove skid plate and drain fluid.
2) Mark front and rear output shaft yokes to drive shafts for
reassembly reference. Support transfer case and remove rear
crossmember. Remove drive shafts.
3) Disconnect vehicle speed sensor electrical connector and
vacuum (hoses) harness at transfer case. Remove shift lever or linkage\
rod from case. Remove transfer case attaching bolts. Remove transfer
case from vehicle.