JEEP CHEROKEE 1994 Service Repair Manual

(23) Remove front output shaft (Fig. 18).
(24) Remove transfer case shift lever nut and lever.
(25) Remove shift detent plug, spring and pin (Fig.
19).(26) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole (Fig. 20).
(27) Remove range fork lockpin with size number
one easy-out tool. Grip easy-out tool with locking pli-
ers and remove pin with counterclockwise, twist and
pull motion (Fig. 20).
(28) Remove shift rail by pulling it straight up and
out of fork (Fig. 21).
Fig. 18 Removing Front Output Shaft
Fig. 19 Removing Detent Components
Fig. 20 Removing Low Range Fork Lockpin
Fig. 21 Removing Shift Rail
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(29) Remove mode fork and mainshaft as assembly
(Fig. 22).
(30) Remove mode shift sleeve and mode fork as-
sembly from mainshaft (Fig. 23). Note position of
mode sleeve in fork and remove sleeve.(31) Remove intermediate clutch shaft snap ring
(Fig. 24).
(32) Remove clutch shaft thrust ring (Fig. 25).
Fig. 22 Removing Mode Fork And Mainshaft
Fig. 23 Removing Mode Fork And Sleeve
Fig. 24 Removing Intermediate Clutch Shaft Snap
Ring
Fig. 25 Removing Clutch Shaft Thrust Ring
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(33) Remove intermediate clutch shaft (Fig. 26).
(34) Remove differential snap ring (Fig. 27).(35) Remove differential (Fig. 28).
(36) Remove differential needle bearings and both
needle bearing thrust washers from mainshaft.
(37) Slide low range fork pin out of shift sector slot
(Fig. 29)
Fig. 26 Removing Intermediate Clutch Shaft
Fig. 27 Removing Differential Snap Ring
Fig. 28 Differential Removal
Fig. 29 Disengage Low Range Fork
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(38) Remove low range fork and hub (Fig. 30).
(39) Remove the shift sector (Fig. 31).(40) Remove shift sector bushing and O-ring (Fig.
32).
(41) Remove front bearing retainer bolts.
(42) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 33). Position the
screwdriver in the slots cast into retainer.
Fig. 30 Removing Low Range Fork And Hub
Fig. 31 Shift Sector Position
Fig. 32 Removing Sector Bushing And O-Ring
Fig. 33 Removing Front Bearing Retainer
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(43) Remove the input gear snap ring (Fig. 34).
(44) Press input and low range gears out of input
gear bearing and case (Fig. 35).(45) Remove the low range gear snap ring (Fig.
36).
(46) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 37).
Fig. 34 Removing Input Gear Snap Ring
Fig. 35 Removing Input And Low Range Gears
Fig. 36 Removing/Installing Low Range Gear Snap
Ring
Fig. 37 Low Range Gear Disassembly
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(47) Inspect the low range annulus gear (Fig. 38).
The gear is not a serviceable component. If
damaged, replace the gear and front case as an
assembly.
(48) Remove the oil seals from the rear retainer,
extension housing, oil pump and case halves.
(49) Mark differential case halves for reference.
(50) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 39).
(51) Remove thrust washers and planet gears from
case pins (Fig. 40).(52) Remove mainshaft and sprocket gears from
bottom case (Fig. 41). Note gear position for reference
before separating them.
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 dry it
with compressed air. Also use compressed air to re-
move solvent residue from all oil feed passages and
channels.
Fig. 38 Inspecting Low Range Annulus Gear
Fig. 39 Separating Differential Case Halves
Fig. 40 Removing Planet Gears And Thrust Washers
Fig. 41 Removing Mainshaft And Sprocket Gears
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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 the transfer case components with
automatic transmission fluid or petroleum jelly
(where indicated) 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 the front output shaft, front bearing
snap ring (Fig. 42).(3) Remove the old bearing and install the new
bearing with a driver handle and installer tool (Fig.
43).
(4) Install the front bearing snap ring (Fig. 42).
(5) Install new front output shaft oil seal (Fig. 44).
Fig. 42 Removing/Installing Front Output Shaft
Front Bearing Snap Ring
Fig. 43 Replacing Output Shaft Front Bearing
Fig. 44 Installing Front Output Shaft Seal
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(6) Press input gear bearing out of front case with
driver tool and shop press (Fig. 45).
(7) Install the snap ring on the new bearing.
(8) Install the new input gear bearing with a shop
press and wood block. Install the bearing far enough
to seat the snap ring against the case (Fig. 46).(9) Remove input gear pilot bearing with slide
hammer and internal puller (Fig. 47).
(10) Install new pilot bearing with driver tools
(Fig. 48).
Fig. 45 Removing Input Gear Bearing
Fig. 46 Seating Input Gear Bearing
Fig. 47 Removing Input Gear Pilot Bearing
Fig. 48 Installing Input Gear Pilot Bearing
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(11) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 49).
(12) Install low range gear snap ring (Fig. 50).
(13) Lubricate input gear and low range gears with
automatic transmission fluid.
(14) Start the input gear shaft into the front case
bearing.
(15) Press the input gear shaft into the front bear-
ing.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. 51). Also, do not press against the end sur-
faces of the low range gear. The gear case and
thrust washers could be damaged.
(16) Install new input gear snap ring (Fig. 52).
Fig. 49 Low Range And Input Gear Assembly
Fig. 50 Install Low Range Gear Snap Ring
Fig. 51 Input Gear Installation
Fig. 52 Install Input Gear Snap Ring
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(17) Install new seal in front bearing retainer (Fig.
53).
(18) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker. silicone adhesive sealer, or Loctite 518 to
seal surface of front bearing retainer.
(19) Install the front bearing retainer (Fig. 54).
Tighten the retainer bolts to 16 ft. lbs. (21 Nzm)
torque.(20) Install new sector shaft O-ring and bushing
(Fig. 55).
(21) Install the shift sector.
(22) Install new pads in low range fork (Fig. 56).
(23) Assemble low range fork and hub (Fig. 56).
Fig. 55 Installing Sector O-Ring And Bushing
Fig. 56 Assembling Low Range Fork And Hub
Fig. 53 Install Front Bearing Retainer Seal
Fig. 54 Installing Front Bearing Retainer
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