lock JEEP CHEROKEE 1995 Service Repair Manual

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. Shake ex-
cess solvent from screen and allow it air dry. Use
compressed air to remove solvent residue from all oil
feed passages and channels in the case halves.
Inspect the splines and bearing surfaces on the
both shafts. Replace either shaft as necessary if wear,
or damage is evident.
Check condition of the shift forks, fork pads and
shift rail. Minor scratches/nicks on the rail can be
smoothed with 320/400 grit emery cloth. Replace the
mode fork pads if worn. Replace the range fork if the
pads are worn, missing, or damaged.
On synchro equipped models, inspect the synchro
sleeve, hub, struts, springs, and the stop ring. Re-
place worn, or damaged parts as necessary.
Do not attempt to salvage and reuse snap rings
that were bent, or distorted. It is recommended that
all snap rings be replaced during overhaul.Replace the front yoke nut as it should not be re-
used. Also replace the rubber seal if worn, cut, or
torn.
Inspect the low range annulus gear (Fig. 28).If
the gear is damaged, replace the gear and front
case as an assembly. Do not attempt to remove
the gear.
Inspect the case halves, extension housing and re-
tainers for cracks, porosity, or damaged sealing sur-
faces.
Inspect the drive sprockets and drive chain care-
fully. Replace the sprockets if worn, chipped, or
cracked. Also replace the chain if distorted, binds at
any point, or is stretched.
Replace the oil pump if any pump part is worn or
damaged. Do not disassemble the pump as parts are
not available separately. The pump is only available
as an assembly.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam-
aged bearings as outlined in the transfer case assem-
bly procedures.
Clean the sealing (mating) surfaces of the case
halves, retainer and extension with a scraper, a wire
brush and 3M All Purpose cleaning solvent. These
surfaces must be clean in order for the sealer to ad-
here properly.
TRANSFER CASE 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.
In addition, the drive sprocket, synchro hub and
sleeve are different for non-synchro and synchro
models. Do not interchange these parts. Do not in-
stall synchro struts or a stop ring in a non-synchro
model; this will cause the drive sprocket to bind on
the shaft and hub.
Fig. 26 Removing Low Range Gear Snap Ring
Fig. 27 Input And Low Range Gear Components
Fig. 28 Low Range Annulus Gear Location
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(8) Remove input gear bearing from front case
with Tool Handle C-4171 and Tool C-4210, 7828, or
5062. Use tool that is best fit in bearing (Fig. 34).
(9) Turn front case over.
(10) Start bearing in case by hand. Then seat bear-
ing with Tools C-4171 and C-4210, or 7828 until snap
ring seats against case surface (Fig. 35).
INPUT AND LOW RANGE GEAR ASSEMBLY
AND INSTALLATION
(1) Remove mainshaft pilot bearing from input
gear with Tool MD-998346, or similar tool as follows:
(a) Turn puller tool bolt until jaws retract
enough to fit into bearing (Fig. 36).
(b) Insert puller bolt and jaws into bearing. Then
turn puller bolt clockwise so ramp on bolt spreads
jaws forcing them under bearing (Fig. 37).
Fig. 34 Input Gear Bearing Removal
Fig. 35 Input Gear Bearing Installation
Fig. 36 Puller Jaws In Retracted Position
Fig. 37 Puller Bolt And Jaws Seated Under Needle
Bearing
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(c) Install puller bridge over puller bolt (Fig. 38).
Then install flat washer and nut on bolt.
(d) Hold puller bridge from turning by hand or
with locking pliers. Then tighten nut on puller bolt
in clockwise direction to draw bearing out of input
gear (Fig. 39).
(2) Install new needle bearing in input gear with
Tool Handle C-4171 and Installer 5065 (Fig. 40).
(3) Lubricate and install thrust washers, input
gear and retainer in low range gear (Fig. 41). Then
install retainer snap ring.Be sure snap ring is
fully seated before proceeding.
(4) Align and install input/low range gear assembly in
case. Use hammer handle to tap low range gear into an-
nulus and input gear into bearing if necessary.
(5) Install input gear snap ring (Fig. 42).
(6) Install new oil seal in input bearing retainer
with suitable size installer tool (Fig. 43).
(7) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
Fig. 38 Installing Puller Bridge
Fig. 39 Removing Mainshaft Pilot Bearing From
Input Gear
Fig. 40 Installing Mainshaft Pilot Bearing In Input
Gear
Fig. 41 Input And Low Range Gear Components
Fig. 42 Installing Input Gear Snap Ring
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MAINSHAFT ASSEMBLY
(1) If drive sprocket bearings are to be replaced,
remove and install them as follows:
(a) Press both bearings out of sprocket simulta-
neously with Tool Handle C-4171 and Remover Tool
C-4667, or 5066 (Fig. 53).
(b) Before installing new bearings, refer to Figure
54 and note correct bearing position in sprocket. Bear-ings must also be installed in proper sequence. Install
front bearing first and rear bearing last.
CAUTION: Do not press the bearings any farther
into the sprocket than indicated in Figure 54. The
bearings could block the mainshaft oil feed hole if
pressed too deeply into the sprocket.
(c) Install newfrontbearing first. Press bearing
flush with edge of sprocket bore (Fig. 55).
(d) Install newrearbearing (Fig. 56). Press
bearing in until 4.6 mm (3/16 in.) below edge of
bore as shown in Figure 46.
(2) On synchro models, install struts and spring(s)
in hub (Fig. 57).
(3) Lubricate drive sprocket bearings, stop ring
and hub with automatic transmission fluid. Bearings
can also be lubricated with petroleum jelly if desired.
(4) Install sprocket, stop ring (synchro models
only) and hub on mainshaft (Fig. 58).Be sure to
seat hub struts on stop ring lugs.
(5) Install spacer washer on hub, if equipped.
Fig. 54 Correct Bearing Position In Drive Sprocket
Fig. 53 Drive Sprocket Bearing Removal
Fig. 55 Installing Drive Sprocket Front Bearing
Fig. 56 Installing Drive Sprocket Rear Bearing
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SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig. 3).
4) Verify that linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully en-
gaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
(8) Verify proper shift operation.
SHIFT LEVER REMOVAL (XJ)
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to park brake section in
Group 5 for procedures.
(6) Remove screws attaching lever assembly to floor-
pan and remove assembly and shift rod (if left attached).
SHIFT LEVER INSTALLATION (XJ)
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install as-
sembly attaching screws.
(2) Install console.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever.
(5) Tighten trunnion lock bolt.
(6) Lower vehicle.
(7) Lower vehicle.
(8) Remove shift lever spacer and install bezel.
SPEEDOMETER SERVICE
Speedometer service procedures are covered in the
automatic transmission sections within Group 21.
Refer to these sections when necessary.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Place support stand under transmission.
(6) Remove rear crossmember.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and re-
move sensor and adapter assembly if necessary.
(9) Disconnect shift rod from transfer case range
lever.
(10) Disconnect transfer case vent hoses and elec-
trical switch connector.
(11) Support transfer case with transmission jack.
(12) Remove bolts attaching transfer case to trans-
mission.
(13) Secure transfer case to jack with chains.
(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
(16) If transfer case was removed for overhaul, re-
move damper from rear retainer.
TRANSFER CASE INSTALLATION
(1) Install damper on transfer case rear retainer, if
equipped (Fig. 4). Tighten damper attaching nuts to
54 Nzm (40 ft. lbs.) torque.
(2) Mount transfer case on transmission jack. Se-
cure transfer case to jack with safety chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts and
slide transfer case onto transmission.
(5) Install and tighten transfer case attaching nuts
to 35 Nzm (26 ft. lbs.) torque.
Fig. 3 Shift Linkage (XJ)
JNP242 TRANSFER CASE 21 - 309

(6) Install vehicle speed sensor and adapter, if re-
moved. Then connect vehicle speed sensor wires, vent
hoses and electrical switch connector.
(7) Align and connect propeller shafts. Tighten
shaft U-joint clamp bolts to 19 Nzm (14 ft. lbs.)
torque.
(8) Fill transfer case with Mopar Dexron II. Cor-
rect fill level is to bottom edge of fill plug hole.
(9) Install rear crossmember. Tighten crossmember
bolts to 41 Nzm (30 ft. lbs.) torque.
(10) Remove transmission jack and transmission
support stand.
(11) Move transfer case range lever to 4L position.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage as described
in this section.
(14) Lower vehicle.
TRANSFER CASE DISASSEMBLY AND OVERHAUL
(1) Remove fill and drain plugs.
(2) Remove front yoke. Discard yoke seal washer
and nut.
(3) Place transfer case range lever in 4L position.
(4) Remove extension housing attaching bolts.
(5) Tap extension housing in a clockwise direction
to break sealer bead and remove housing (Fig. 1).
CAUTION: To avoid damaging the sealing surfaces
of the extension housing and rear retainer, do not
attempt to pry or wedge the housing off the re-
tainer.
(6) Remove rear bearing snap ring from mainshaft
(Fig. 2). Discard snap ring.
(7) Remove rear retainer attaching bolts.
(8) Loosen rear retainer (Fig. 3). Position long
screwdriver under each tab at ends of retainer hous-
ing and pry retainer upward.CAUTION: Do not pry against the sealing surfaces
of the retainer or rear case. The surfaces could be
damaged.
(9) Lift rear retainer up and off case and main-
shaft (Fig. 4).
(10) Remove bolts attaching rear case to front case.
Retain bolts and the washers.
(11) Loosen rear case with two screwdrivers (Fig.
5). Insert screwdrivers into slots cast in case ends.
Then gently pry upward to break sealer bead.
Fig. 4 Damper Mounting
Fig. 1 Extension Housing Removal
Fig. 2 Removing Rear Bearing Snap Ring
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(20) Remove drive sprocket and chain (Fig. 11).
(21) Remove front output shaft (Fig. 12).(22) Remove transfer case shift lever nut and lever.
(23) Remove shift detent plug, spring and pin (Fig.
13)
(24) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole (Fig. 14).
(25) 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. 14).
fig. 11 Drive Sprocket And Chain Removal
Fig. 12 Removing Front Output Shaft
Fig. 13 Detent Component Removal
Fig. 14 Low Range Fork Lockpin 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
JNP242 TRANSFER CASE 21 - 319

(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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(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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