transfer case JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual

(5) Remove rear bearing snap-ring.
(6) Remove rear bearing. Note position of bearing
locating ring groove for assembly reference.
(7) Disengage oil pickup tube from oil pump and
remove oil pump assembly (Fig. 11).
(8) Remove pick-up tube o-ring from oil pump (Fig.
12), if necessary. Do not disassemble the oil pump, it
is not serviceable.
COMPANION FLANGE AND RANGE LEVER
(1) Remove front companion flange nut as follows:
(a) Move range lever to 4L position.
(b) Remove nut with socket and impact wrench.
(2) Remove companion flange. If flange is difficult
to remove by hand, remove it with bearing splitter, orwith standard two jaw puller. Be sure puller tool is
positioned on flange and not on slinger as slinger will
be damaged.
(3) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(4) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft.
NOTE: Note position of range lever so it can be re-
installed correctly.
Fig. 9 Disengaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
Fig. 10 Rear Retainer Removal
1 - REAR CASE
2 - REAR RETAINER
Fig. 11 Rear Bearing and Oil Pump Removal
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 12 Pick-up Tube O-ring Location
1 - OIL PUMP
2 - O-RING
WJTRANSFER CASE - NV247 21 - 319
TRANSFER CASE - NV247 (Continued)

REAR CASE
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case.
The case alignment bolt require flat washers (Fig.
13).
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert screwdriver blade only into
notches provided at each end of case (Fig. 14).
(4) Remove rear case (Fig. 15).
PROGRESSIVE COUPLING
(1) Remove oil pump locating snap-ring and pro-
gressive coupling thrust washer from the mainshaft
(Fig. 16).
(2) Remove progressive coupling from mainshaft
(Fig. 16).
Fig. 13 Rear Case Alignment Bolt Locations
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 14 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
Fig. 15 Rear Case Removal
1 - REAR HOUSING
2 - MAINSHAFT
3 - TRANSFER CASE
Fig. 16 Progressive Coupling Removal
1 - SNAP-RING
2 - PROGRESSIVE COUPLING
21 - 320 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove oil pickup tube from rear case (Fig.
17).
(2) Remove drive gear snap-ring (Fig. 18).
(3) Disengage drive gear (Fig. 18). Pry gear
upward and off mainshaft as shown.
(4) Remove front output shaft, drive chain and
drive gear as assembly (Fig. 18).
(5) Remove output shaft drive gear snap ring.
(6) Remove output shaft drive gear from output
shaft.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 19).
(2) Remove shift rail from shift fork and transfer
case housing.
(3) Rotate range shift fork until it disengages from
shift sector.
(4) Remove mainshaft and shift fork from input
gear pilot bearing.
NOTE: Loose needle bearings are used to support
the drive sprocket hub on the mainshaft. Do not lift
mainshaft by drive sprocket hub or needle bearings
will become dislodged.
(5) Wrap rag around mainshaft underneath drive
sprocket hub and remove drive sprocket hub from
mainshaft. Be sure to retrieve all the drive sprocket
hub needle bearings.
(6) Remove snap ring holding clutch sleeve onto
mainshaft.
Fig. 17 Oil Pickup Tube Removal
1 - OIL PICKUP TUBE
Fig. 18 Front Output Shaft, Drive Gear And Chain
Removal
1 - REAR HOUSING
2 - OUTPUT SHAFT AND SPROCKET
3 - MAINSHAFT SPROCKET
4 - SNAP-RING
5 - DRIVE CHAIN
Fig. 19 Detent Plug, Spring And Plunger Removal
1 - DETENT PLUG
2 - DETENT SPRING
3 - DETENT PLUNGER
4 - PLUG O-RING
WJTRANSFER CASE - NV247 21 - 321
TRANSFER CASE - NV247 (Continued)

(7) Remove range clutch sleeve, blockout spring,
locking clutch, and locking clutch spring from main-
shaft (Fig. 20).
(8) Remove shift sector. Rotate and tilt sector as
needed to remove it (Fig. 21).
(9) Remove shift sector bushing and O-ring (Fig.
22).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Turn front case on side so front bearing
retainer is accessible.
(2) Remove front bearing retainer bolts (Fig. 23).
(3) Remove front bearing retainer as follows:(a) Loosen retainer with flat blade screwdriver
to break sealer bead.To avoid damaging case
and retainer, position screwdriver blade only
in slots provided in retainer (Fig. 24).
(b) Then remove retainer from case and gear.
Fig. 20 Range Clutch Sleeve, Blockout Spring,
Locking Clutch and Spring
1 - LOCKING CLUTCH SPRING
2 - BLOCKOUT SPRING
3 - SNAP-RING
4 - RANGE CLUTCH SLEEVE
5 - LOCKING CLUTCH
6 - DRIVE SPROCKET HUB
Fig. 21 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 22 Sector Bushing And O-Ring Removal
1 - SHIFT SECTOR BUSHING
2 - O-RING
Fig. 23 Front Bearing Retainer Bolt Removal
1 - FRONT BEARING RETAINER
21 - 322 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(4) Remove snap-ring that retains input gear shaft
in front bearing (Fig. 25).
(5) Remove input and low range gear assembly
(Fig. 26).
(6) Remove oil seals from following components:
²front bearing retainer.
²rear retainer.
²case halves.INPUT AND LOW RANGE GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 27).
Fig. 24 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER NOTCH
3 - FLAT BLADE SCREWDRIVER
Fig. 25 Input Gear Snap-Ring Removal
1 - INPUT GEAR
2 - SNAP-RING
Fig. 26 Input And Low Range Gear Assembly
Removal
1 - INPUT AND LOW RANGE GEAR ASSEMBLY
Fig. 27 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
WJTRANSFER CASE - NV247 21 - 323
TRANSFER CASE - NV247 (Continued)

(2) Remove retainer (Fig. 28).
(3) Remove front tabbed thrust washer (Fig. 29).
(4) Remove input gear (Fig. 30).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 31).
CLEANING
Clean the transfer case components with parts
cleaning solvent. Flush the oil passages in the cases
and drivetrain components with solvent. This will
help remove dirt and particles from these passages.
Dry the transfer case components with compressed
air or allow them to air dry on clean shop towels.
Apply compressed air through all oil passages in
the cases and gear components to clear them of any
residue.
INSPECTION
MAINSHAFT
Examine the mainshaft components carefully for
evidence of wear or damage.
Replace the thrust washers if worn or damaged.
Replace the mainshaft and sprocket gears if the
teeth or gear bores are worn or damaged.
Replace the mainshaft bearings if worn, flat spot-
ted, brinelled, or damaged in any way.
Replace the mainshaft if it is bent, exhibits wear or
damage to the bearing surfaces, splines or gear teeth.
Fig. 28 Input Gear Retainer
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 29 Front Tabbed Thrust Washer
1 - FRONT TABBED THRUST WASHER
Fig. 30 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 31 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 324 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

INPUT AND LOW RANGE GEARS
Inspect the low range gear pinions and pinion pins.
Replace the low range gear if any of the pins or pin-
ions are worn or damaged.
Inspect the thrust washers, retainer, and snap-
ring. Replace the snap-ring if bent, or distorted.
Replace the thrust washers and retainer if worn,
cracked or damaged in any way.
Examine the input gear carefully. Be sure the gear
teeth and bearing surfaces are in good condition.
Replace the gear if wear or damage is evident.
Check the input gear pilot bearing. Rotate the
bearing and check for roughness or noise. Also check
bearing position in the bore. The bearing should be
recessed approximately 2.5 mm (0.100 in.) below the
top edge of the bore. The bearing should not be
seated at the bottom of the bore. Replace the bearing
if worn, or roughness is evident. Replace both the
gear and bearing if the bearing is a loose fit in the
bore.
GEAR CASE AND RETAINERS
Examine both case halves and retainers carefully.
Replace any retainer or case half if wear, cracks, or
other damage is evident.
Check condition of the low range annulus gear and
the shift rail bushing in the front case (Fig. 32). The
low range annulus gear is not a serviceable part.
Replace the gear and case as an assembly if the gear
is loose, worn, or damaged. The shift rail bushing is
a serviceable part and can be replaced if necessary.
Check the bushing in the rear retainer. Replace the
bushing if worn or scored.
Examine the sealing surfaces of both case halves
and retainers. Small burrs, or scratches on these sur-
faces can be reduced with crocus cloth or a fine tooth
file.
Examine condition of the shift rail bushing in the
front case. If the bushing is worn or damaged, it can
be removed with a blind hole type puller. A replace-
ment bushing can be installed with a suitable size
driver. Recess the bushing slightly below the edge of
the bore but do not seat it all the into the case.
GEARTRAIN
Inspect the mainshaft splines, gear teeth and bear-
ing surfaces carefully for evidence of wear, or dam-
age. Replace the shaft if necessary. do not attempt to
salvage it if damaged.
The shift rail and range fork are an assembly.
Replace both parts if either is damaged. However, the
nylon pads in the fork can be replaced if worn, or
cracked.
Inspect the transfer case snap-rings closely. Do not
attempt to salvage a distorted snap-ring by straight-ening or reshaping it. Replace any snap-ring that is
distorted, or worn.
Inspect the low range gear, input gear and the gear
thrust washers retainer, and snap-ring. The low
range gear is serviced as an assembly only. Replace
the gear if the case or pinions are damaged.
During inspection, also make sure the seal surface
of the input gear is in good condition. Minor nicks on
this surface can be reduced with crocus cloth. How-
ever, replace the gear if the seal surface is severely
scored or worn.
OIL PUMP AND PROGRESSIVE COUPLING
The oil pump and progressive coupling are not ser-
viceable components. Replace the coupling as an
assembly if it is damaged. Replace the oil pump as
an assembly if the gear teeth are worn, or if the
pump has become damaged.
BEARINGS AND SEALS
The transfer case seals should be replaced during
overhaul. Use new seals in the input gear bearing
retainer, front case and rear retainer. Also replace
the yoke seal washer and the detent plug O-ring.
Check condition of each transfer case bearing.
Replace any bearing exhibiting signs of roughness,
wear, or damage.
Fig. 32 Low Range Annulus Gear Location
1 - LOW RANGE ANNULUS GEAR
2 - SHIFT RAIL BUSHING
WJTRANSFER CASE - NV247 21 - 325
TRANSFER CASE - NV247 (Continued)

ASSEMBLY
Lubricate transfer case components with Mopart
Transfer Case Lubricant or petroleum jelly (where
indicated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
BEARINGS AND SEALS
(1) Remove front output shaft seal from front case
with pry tool (Fig. 33).
(2) Remove snap-ring that retains front output
shaft bearing in front case (Fig. 34).
(3) Using tool 6953, remove bearing from front
case (Fig. 35).
(4) Using tool 6953, install new bearing.
(5) Install snap-ring to hold bearing into case.
Fig. 33 Remove Front Output Shaft Seal
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 34 Output Shaft Front Bearing Snap-Ring
Removal
1 - FRONT CASE
2 - OUTPUT SHAFT FRONT BEARING
3 - BEARING SNAP-RING
Fig. 35 Remove Output Shaft Front Bearing
1 - HANDLE C-4171
2 - REMOVER/INSTALLER 6953
21 - 326 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(6) Install new front output seal in front case with
Installer Tool 6952-A as follows:
(a) Place new seal on tool.Garter spring on
seal goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 36). Once seal is started, continue tap-
ping seal into bore until installer tool bottoms
against case.
(7) Remove the output shaft rear bearing with the
screw and jaws from Remover L-4454 and Cup 8148
(Fig. 37).(8) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 38).The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig.
39).
Fig. 37 Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 36 Front Output Seal Installation
1 - INSTALLER 6952-A
2 - TRANSFER CASE
Fig. 38 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 39 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
WJTRANSFER CASE - NV247 21 - 327
TRANSFER CASE - NV247 (Continued)

(9) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing from inside the annulus
gear opening in the case. (Fig. 40).
(10) Install locating ring on new bearing.
(11) Position case so forward end is facing upward.
(12) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing into case. The bearing
locating ring must be fully seated against case sur-
face (Fig. 41).
(13) Remove input gear pilot bearing by inserting
a suitably sized drift into the splined end of the inputgear and driving the bearing out with the drift and a
hammer (Fig. 42).
(14) Install new pilot bearing with Installer 8128
and Handle C-4171 (Fig. 43).
Fig. 40 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 41 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 42 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 43 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
21 - 328 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)