24 -25 JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual
[x] Cancel search | Manufacturer: JEEP, Model Year: 2002, Model line: GRAND CHEROKEE, Model: JEEP GRAND CHEROKEE 2002 WJ / 2.GPages: 2199, PDF Size: 76.01 MB
Page 181 of 2199
SPECIFICATIONS
BRAKE COMPONENTS
SPECIFICATIONS
DESCRIPTION SPECIFICATION
Front Disc Brake Caliper
TypeFloating
Front Disc Brake Caliper
Piston48 mm (1.889 in.)
Front Disc Brake Rotor
TypeVentilated
Front Disc Brake Rotor
Diameter305 mm (12 in.)
Front Disc Brake Rotor
Max. Runout0.05 mm (0.002 in.)
Front Disc Brake Rotor
Max. Thickness Variation0.0127 mm (0.0005 in.)
Front Disc Brake Rotor
Min. Thickness24.5 mm (0.9646 in.)
Rear Disc Brake Caliper
TypeFloatingDESCRIPTION SPECIFICATION
Rear Disc Brake Caliper
Piston48 mm (1.889 in.)
Rear Disc Brake Rotor
Type DiameterSolid
Rear Disc Brake Rotor
Diameter305 mm (12 in.)
Rear Disc Brake Rotor
Max. Runout0.76 mm (0.003 in.)
Rear Disc Brake Rotor
Max. Thickness Variation0.0127 mm (0.0005 in.)
Rear Disc Brake Rotor
Min. Thickness8.5 mm (0.335 in.)
Rear Disc Brake Rotor
Drum Max. Diameter196 mm (7.7166 in.)
Brake Booster Type Dual Diaphragm
TORQUE CHART
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Brake Pedal Support Bolt 23-24 17-25 Ð
Brake Pedal Pivot Nut 27-35 20-26 Ð
Brake Pedal Bracket
Adjustable pedals28 21 250
Brake Pedal Bracket To Dash 12 9 105
Brake Booster Mounting Nuts 39 29 Ð
Master Cylinder Mounting Nuts 25 18 Ð
Master Cylinder Primary Brake Line 16 Ð 144
Master Cylinder Secondary Brake Line 16 Ð 144
Front Caliper Slide Pins 29-41 21-30 Ð
Front Caliper Anchor Bolts 90-115 66-85 Ð
Front Caliper Brake Hose Banjo Bolt 31 23 Ð
Front Caliper Bleed Screw 16 Ð 144
Rear Caliper Slide Pins 29-41 21-30 Ð
Rear Caliper Anchor Bolts 90-115 66-85 Ð
Rear Caliper Brake Hose Banjo Bolt 31 23 Ð
Rear Caliper Bleed Screw 16 Ð 144
5 - 6 BRAKES - BASEWJ
BRAKES - BASE (Continued)
Page 706 of 2199
8W-12 JUNCTION BLOCK
Component PageA/C Compressor Clutch Relay................8W-12-18
Accessory Delay Relay.....................8W-12-25
Adjustable Pedals Module..................8W-12-11
Airbag Control Module....................8W-12-25
Auto Shut Down Relay....................8W-12-18
Automatic Day/Night Mirror.................8W-12-23
Automatic Headlamp Light Sensor/VTSS LED......8W-12-15
Automatic Zone Control Module..........8W-12-15, 17, 22
Back-Up Lamp Relay.....................8W-12-22
Body Control Module . . . 8W-12-10, 12, 13, 15, 17, 20, 23, 24, 25,
26, 27, 28, 29, 30, 31, 35, 36
Brake Lamp Switch......................8W-12-24
Cargo Lamp......................8W-12-16, 24, 27
Cigar Lighter..........................8W-12-17
Cigar Lighter Relay....................8W-12-17, 26
Circuit Breaker No. 1...................8W-12-28, 29
Circuit Breaker No. 2......................8W-12-9
Clockspring...........................8W-12-31
Combination Flasher............8W-12-10, 22, 27, 32, 35
Controller Antilock Brake..................8W-12-21
Data Link Connector.....................8W-12-10
Driver Door Module......................8W-12-34
Driver Heated Seat Switch..................8W-12-22
Driver Lumbar Switch.....................8W-12-9
Driver Power Seat Switch...................8W-12-9
Electric Brake..........................8W-12-21
Engine Control Module....................8W-12-19
Engine Starter Motor Relay.................8W-12-26
EVAP/Purge Solenoid.....................8W-12-18
Fog Lamp Relay........................8W-12-24
Front Power Outlet......................8W-12-11
Front Wiper Motor....................8W-12-28, 29
Fuel Pump Relay........................8W-12-18
Fuse 2..............................8W-12-17
Fuse 3............................8W-12-10, 20
Fuse 4..............................8W-12-10
Fuse 5..............................8W-12-11
Fuse 6............................8W-12-12, 13
Fuse 7..............................8W-12-15
Fuse 8..............................8W-12-16
Fuse 9..............................8W-12-11
Fuse 10..............................8W-12-11
Fuse 11..............................8W-12-17
Fuse 12.......................8W-12-18, 19, 21, 34
Fuse 14..............................8W-12-20
Fuse 15.........................8W-12-11, 15, 20
Fuse 16..............................8W-12-10
Fuse 17..............................8W-12-10
Fuse 18...........................8W-12-21, 34
Fuse 19..............................8W-12-21
Fuse 20..............................8W-12-22
Fuse 21...........................8W-12-18, 19
Fuse 22..............................8W-12-23
Fuse 23..............................8W-12-24
Fuse 24..............................8W-12-24
Fuse 25..............................8W-12-25
Fuse 26..............................8W-12-17
Fuse 27..............................8W-12-36
Fuse 28..............................8W-12-26
Fuse 29..............................8W-12-26
Fuse 30..............................8W-12-26
Fuse 31..............................8W-12-26
Fuse 32..............................8W-12-25
Fuse 33..............................8W-12-25
G200...............................8W-12-35
Glove Box Lamp........................8W-12-16
Headlamp Leveling Switch...............8W-12-12, 13
High Beam Relay........................8W-12-10
Horn Relay...........................8W-12-31
Horn Switch...........................8W-12-31
Instrument Cluster..................8W-12-10, 23, 32
Intrusion Transceiver Module................8W-12-16
Junction Block.........8W-12-2, 3, 9, 10, 11, 12, 13, 15, 16,
17, 18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32, 34, 35, 36Component PageLeft Courtesy Lamp......................8W-12-16
Left Door Handle Courtesy Lamp.........8W-12-16, 24, 30
Left Fog Lamp.........................8W-12-24
Left Front Park Lamp.....................8W-12-14
Left Front Park/Turn Signal Lamp...........8W-12-14, 33
Left Front Side Marker Lamp..............8W-12-14, 33
Left Front Turn Signal Lamp................8W-12-33
Left Headlamp Leveling Motor...............8W-12-14
Left High Beam Headlamp..................8W-12-10
Left Liftgate Ajar Switch...................8W-12-30
Left Low Beam Headlamp..................8W-12-20
Left Multi-Function Switch...............8W-12-10, 35
Left Rear Door Lock Motor/Ajar Switch..........8W-12-27
Left Rear Lamp Assembly...........8W-12-12, 13, 27, 36
Left Side Repeater Lamp...................8W-12-32
Left Visor/Vanity Lamp..................8W-12-16, 30
License Lamp No. 1....................8W-12-12, 13
License Lamp No. 2....................8W-12-12, 13
Liftgate Flip-Up Ajar Switch.................8W-12-30
Liftgate Flip-Up Push Button Switch...........8W-12-16
Liftgate Power Lock Motor..................8W-12-16
Low Beam Relay........................8W-12-20
Low Beam/Daytime Running Lamp Relay.........8W-12-20
Manual Temperature Control..............8W-12-17, 22
Overhead Map/Courtesy Lamp...........8W-12-16, 24, 30
Park Lamp Relay.....................8W-12-12, 13
Park/Neutral Position Switch................8W-12-22
Passenger Door Module....................8W-12-34
Passenger Heated Seat Switch...............8W-12-22
Passenger Lumbar Switch...................8W-12-9
Passenger Power Seat Switch.................8W-12-9
Power Amplifier.........................8W-12-11
Power Connector........................8W-12-11
Power Distribution Center....8W-12-10, 11, 15, 17, 20, 21, 34
Powertrain Control Module.................8W-12-18
Radio.............................8W-12-11, 26
Rain Sensor...........................8W-12-25
Rear Window Defogger....................8W-12-17
Rear Window Defogger Relay................8W-12-17
Rear Wiper Motor.....................8W-12-16, 30
Remote Keyless Module....................8W-12-15
Right Courtesy Lamp.....................8W-12-16
Right Door Handle Courtesy Lamp........8W-12-16, 24, 30
Right Fog Lamp........................8W-12-24
Right Front Park Lamp....................8W-12-14
Right Front Park/Turn Signal Lamp..........8W-12-14, 33
Right Front Side Marker Lamp.............8W-12-14, 33
Right Front Turn Signal Lamp...............8W-12-33
Right Headlamp Leveling Motor..............8W-12-14
Right High Beam Headlamp.................8W-12-10
Right Liftgate Ajar Switch..................8W-12-30
Right Low Beam Headlamp.................8W-12-20
Right Multi-Function Switch.................8W-12-26
Right Rear Lamp Assembly..........8W-12-12, 13, 32, 36
Right Side Repeater Lamp..................8W-12-32
Right Visor/Vanity Lamp.................8W-12-16, 30
Seat Module...........................8W-12-9
Sentry Key Immobilizer Module............8W-12-15, 23
Shifter Assembly......................8W-12-18, 19
Siren...............................8W-12-15
Sunroof Control Module....................8W-12-25
Temperature Valve Actuator.................8W-12-22
Trailer Tow Brake Lamp Relay...............8W-12-21
Trailer Tow Circuit Breaker.................8W-12-17
Trailer Tow Connector.....................8W-12-12
Trailer Tow Left Turn Relay.................8W-12-27
Trailer Tow Right Turn Relay................8W-12-32
Transmission Control Module..............8W-12-18, 26
Transmission Solenoid/TRS Assembly...........8W-12-22
Underhood Lamp........................8W-12-15
Vehicle Information Center...............8W-12-16, 23
Wiper High/Low Relay..................8W-12-28, 29
Wiper On/Off Relay....................8W-12-28, 29
WJ8W-12 JUNCTION BLOCK 8W - 12 - 1
Page 782 of 2199
8W-30 FUEL/IGNITION SYSTEM
Component Page
A/C Compressor Clutch Relay . . . 8W-30-23, 35, 39, 41, 42
A/C Pressure Transducer........ 8W-30-21, 42, 45, 31
Accelerator Pedal Position Sensor........ 8W-30-37, 48
Adjustable Pedals Module................ 8W-30-33
Adjustable Pedals Motor/Sensor Assembly.... 8W-30-33
Adjustable Pedals Switch................ 8W-30-33
Auto Shut Down Relay...... 8W-30-8, 9, 12, 24, 25, 26,
27, 28, 29, 30, 35, 39, 41
Battery Temperature Sensor.......... 8W-30-2, 11, 50
Body Control Module................... 8W-30-46
Boost Pressure Sensor.................. 8W-30-45
Brake Lamp Switch.............. 8W-30-4, 5, 32, 51
Camshaft Position Sensor........ 8W-30-18, 19, 20, 49
Capacitor........................... 8W-30-12
Capacitor No. 1....................... 8W-30-16
Capacitor No. 2....................... 8W-30-17
Clockspring...................... 8W-30-4, 5, 38
Coil On Plug No. 1.................... 8W-30-17
Coil On Plug No. 2.................... 8W-30-16
Coil On Plug No. 3.................... 8W-30-17
Coil On Plug No. 4.................... 8W-30-16
Coil On Plug No. 5.................... 8W-30-17
Coil On Plug No. 6.................... 8W-30-16
Coil On Plug No. 7.................... 8W-30-17
Coil On Plug No. 8.................... 8W-30-16
Coil Rail............................ 8W-30-12
Controller Antilock Brake........... 8W-30-2, 36, 51
Crankcase Heater..................... 8W-30-35
Crankshaft Position Sensor....... 8W-30-18, 19, 20, 49
Data Link Connector............... 8W-30-6, 7, 46
Diagnostic Junction Port.......... 8W-30-6, 7, 33, 46
EGR Solenoid........................ 8W-30-50
Electronic Speed Control Servo........... 8W-30-4, 5
Engine Control Module.... 8W-30-34, 35, 36, 37, 38, 39,
40, 41, 42, 43, 44, 45,
46, 47, 48, 49, 50, 51
Engine Coolant Temperature Sensor . . . 8W-30-21, 22, 47
Engine Oil Pressure Sensor......... 8W-30-21, 22, 45
Engine Starter Motor Relay......... 8W-30-18, 19, 39
EVAP/Purge Solenoid.................. 8W-30-4, 5
Fuel Injector No. 1............... 8W-30-13, 15, 44
Fuel Injector No. 2............... 8W-30-13, 14, 44
Fuel Injector No. 3............... 8W-30-13, 15, 44
Fuel Injector No. 4............... 8W-30-13, 14, 44
Fuel Injector No. 5............... 8W-30-13, 15, 44
Fuel Injector No. 6.................. 8W-30-13, 14
Fuel Injector No. 7..................... 8W-30-15
Fuel Injector No. 8..................... 8W-30-14
Fuel Pressure Sensor................... 8W-30-37
Fuel Pressure Solenoid.................. 8W-30-47
Fuel Pump Module.................... 8W-30-10
Fuel Pump Relay.................. 8W-30-8, 9, 10
Fuel Tank Module..................... 8W-30-45
Fuse 6........................... 8W-30-8, 42
Fuse 10............................ 8W-30-33
Fuse 11............................ 8W-30-43
Fuse 12......................... 8W-30-8, 9, 40
Fuse 13............................ 8W-30-41
Fuse 16 . . 8W-30-24, 25, 26, 27, 28, 29, 30, 35, 37, 39, 41
Component Page
Fuse 19............................. 8W-30-9
Fuse 21......................... 8W-30-4, 5, 32
Fuse 22............................ 8W-30-34
Fuse 23............................ 8W-30-39
Fuse 24............................. 8W-30-9
Fuse 26..................... 8W-30-8, 12, 41, 47
Fuse 31............................ 8W-30-39
G103....................... 8W-30-8, 34, 39, 46
G104......................... 8W-30-26, 27, 30
G105........................... 8W-30-35, 39
G108........................... 8W-30-23, 43
G123.............................. 8W-30-50
G300............................ 8W-30-4, 33
G301............................ 8W-30-5, 10
Generator...................... 8W-30-3, 23, 35
Glow Plug No. 1...................... 8W-30-42
Glow Plug No. 2...................... 8W-30-43
Glow Plug No. 3...................... 8W-30-42
Glow Plug No. 4...................... 8W-30-43
Glow Plug No. 5...................... 8W-30-42
Glow Plug Relay No. 1............. 8W-30-35, 42, 43
Glow Plug Relay No. 2............. 8W-30-35, 42, 43
Hydraulic Cooling Module . . . 8W-30-3, 24, 25, 30, 31, 43
Idle Air Control Motor.................. 8W-30-20
Intake Air Temperature Sensor....... 8W-30-21, 22, 38
Intake Port Swirl Actuator............... 8W-30-39
Junction Block......... 8W-30-4, 5, 8, 9, 32, 33, 39, 40
Knock Sensor........................ 8W-30-11
Leak Detection Pump................... 8W-30-23
Manifold Absolute Pressure Sensor.... 8W-30-20, 21, 22
Mass Air Flow Sensor.................. 8W-30-37
Output Speed Sensor.................... 8W-30-2
Oxygen Sensor 1/1 Upstream...... 8W-30-25, 26, 28, 29
Oxygen Sensor 1/2 Downstream.... 8W-30-24, 25, 26, 30
Oxygen Sensor 2/1 Upstream........ 8W-30-27, 28, 29
Oxygen Sensor 2/2 Downstream...... 8W-30-24, 27, 30
Oxygen Sensor Downstream Relay . . 8W-30-24, 26, 27, 30
Park/Neutral Position Switch............. 8W-30-33
Power Distribution Center...... 8W-30-8, 9, 12, 24, 25,
26, 27, 28, 29, 30, 34, 35,
37, 39, 41, 42, 43, 47
Powertrain Control Module . . . 8W-30-2, 3, 4, 5, 6, 7, 8, 9,
10, 11, 12, 13, 14, 15, 16, 17,
18, 19, 20, 21, 22, 23, 24, 25,
26, 27, 28, 29, 30, 31, 32
Shifter Assembly............... 8W-30-2, 32, 38, 40
Speed Control Switch No. 1........... 8W-30-4, 5, 38
Speed Control Switch No. 2........... 8W-30-4, 5, 38
Throttle Position Sensor................. 8W-30-20
Transfer Case Position Sensor........... 8W-30-8, 51
Transmission Control
Module............. 8W-30-6, 7, 20, 23, 32, 36, 40
Transmission Control Relay.............. 8W-30-23
Transmission Solenoid................ 8W-30-3, 21
Transmission Solenoid/TRS Assembly....... 8W-30-33
Viscous/Cabin Heater................... 8W-30-39
Viscous/Cabin Heater Relay...... 8W-30-35, 39, 41, 42
Wastegate Solenoid.................... 8W-30-35
Water In Fuel Sensor................... 8W-30-50
WJ8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
Page 1040 of 2199
8W-70 SPLICE INFORMATION
Component PageS100.............................8W-10-11, 12
S102.............................8W-30-21, 45
S104................................8W-15-4
S105...............................8W-30-20
S106.............................8W-10-19, 20
S107............................8W-70-2, 3, 4, 5
S109...............................8W-10-21
S110 ................................8W-70-2
S111................................8W-10-23
S112............................8W-70-2, 3, 4, 5
S113................................8W-31-13
S114 ................................8W-15-2
S115................................8W-10-17
S116................................8W-12-18
S118................................8W-10-22
S119 ..............................8W-31-9, 10
S120...............................8W-30-20
S121...............................8W-10-21
S122...............................8W-31-5, 6
S123.............................8W-10-19, 20
S123...............................8W-30-12
S124...............................8W-10-22
S125................................8W-30-6
S126...............................8W-30-23
S127...............................8W-10-27
S128.............................8W-10-19, 20
S130...............................8W-18-3, 5
S131...............................8W-70-6, 7
S132............................8W-15-9, 10, 11
S133............................8W-15-9, 10, 11
S134...............................8W-15-6, 7
S135...............................8W-10-18
S136...............................8W-10-18
S137...............................8W-10-31
S139................................8W-15-3
S140................................8W-15-7
S141................................8W-15-6
S142..............................8W-12-3, 32
S143..............................8W-12-5, 32
S145................................8W-70-6
S147...............................8W-30-51
S151................................8W-15-5
S152................................8W-15-8
S153...............................8W-12-14
S154...............................8W-12-33
S155...............................8W-12-33
S156...............................8W-12-14
S158................................8W-70-5
S160................................8W-30-11
S162...............................8W-10-26
S163..............................8W-12-7, 15
S165................................8W-51-9
S168...............................8W-10-26
S169...............................8W-30-47
S170...............................8W-30-44
S171...............................8W-30-36
S172...............................8W-30-36
S174................................8W-15-6
S175................................8W-21-2
S176...............................8W-10-26
S200...............................8W-63-12
S201...............................8W-15-15
S202...............................8W-44-10
S203...............................8W-15-14
S204...............................8W-12-22
S205...............................8W-15-15
S206...............................8W-12-22
S207...............................8W-12-16
S208................................8W-44-8
S209................................8W-12-11
S210...............................8W-18-4, 7
S211................................8W-15-13
S212................................8W-53-2
S213................................8W-33-5
S214................................8W-33-5
S215...............................8W-47-13
S216...............................8W-47-13
S217...............................8W-18-10Component PageS221................................8W-12-11
S222...............................8W-30-37
S223............................8W-18-8, 9, 10
S224.............................8W-15-17, 18
S300...............................8W-15-21
S301...............................8W-15-21
S302...............................8W-61-5, 6
S303...............................8W-61-5, 6
S304...............................8W-12-16
S305...............................8W-18-2, 6
S306...............................8W-12-27
S307...............................8W-15-19
S308...............................8W-12-36
S309...............................8W-12-12
S310...............................8W-51-7, 8
S311 ................................8W-51-5
S312...............................8W-18-2, 6
S313...............................8W-51-5, 6
S314................................8W-33-2
S315...............................8W-70-6, 7
S316...............................8W-12-18
S317................................8W-61-5
S318................................8W-61-5
S319...............................8W-12-21
S323................................8W-18-9
S324...............................8W-18-3, 5
S326.............................8W-12-12, 13
S327...............................8W-12-32
S328................................8W-51-7
S329...............................8W-15-17
S330...............................8W-15-16
S331.............................8W-15-17, 18
S332.............................8W-15-17, 18
S333................................8W-47-3
S334................................8W-12-11
S336...............................8W-15-16
S337...............................8W-12-25
S338...............................8W-15-16
S339...............................8W-61-5, 6
S340...............................8W-61-5, 6
S341.............................8W-15-17, 22
S342................................8W-12-9
S345...............................8W-15-19
S346...............................8W-12-16
S347...............................8W-12-30
S348...............................8W-12-24
S349...............................8W-12-23
S351................................8W-70-8
S352................................8W-63-8
S353................................8W-12-9
S355.............................8W-15-18, 21
S356.............................8W-15-21, 22
S357.............................8W-15-16, 18
S358...............................8W-15-22
S359................................8W-50-9
S360................................8W-47-4
S361................................8W-47-4
S362................................8W-47-4
S363................................8W-47-4
S364................................8W-18-5
S365................................8W-39-11
S366...............................8W-12-15
S367...............................8W-12-36
S368................................8W-47-3
S369.............................8W-15-21, 22
S370...............................8W-15-19
S400...............................8W-12-17
S401...............................8W-15-20
S402...............................8W-15-20
S403...............................8W-12-16
S404...............................8W-12-30
S405...............................8W-12-30
S406................................8W-54-6
S407................................8W-54-6
S408...............................8W-15-19
S410...............................8W-15-19
S411 .............................8W-12-12, 13
S412...............................8W-15-20
WJ8W-70 SPLICE INFORMATION 8W - 70 - 1
Page 1827 of 2199
SPECIFICATIONS
TRANSFER CASE - NV242
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 11.8-17.7 -
Bolt, Diff. Case 17-27 12.5-19.9 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-27 11.8-19.9 -
Bolt, Case Half 35-46 25.8-33.9 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 19.9-25 -
Bolt, Rear Retainer 35-46 25.8-33.9 -
Nuts, Mounting 35 25.8 -
Bolts, U-Joint 19 14 -
SPECIAL TOOLS
TRANSFER CASE - NV242
Installer, Seal - C-4076-B
Handle, Universal - C-4171
Remover, Bearing - C-4210
Puller, Slinger - MD-998056-A
Installer - MD-998323
Installer, Bearing - 5064
21 - 308 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)
Page 1829 of 2199
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL
The fill and drain plugs are both in the rear case
(Fig. 92).
(1) Raise vehicle.
(2) Position drain pan under transfer case.
(3) Remove drain and fill plugs and drain lubri-
cant completely.
(4) Install drain plug. Tighten plug to 20-34 N´m
(15-25 ft. lbs.).
(5) Remove drain pan.
(6) Fill transfer case to bottom edge of fill plug
opening with MopartTransfer Case Lubricant.
(7) Install and tighten fill plug to 20-34 N´m
(15-25 ft. lbs.).
(8) Lower vehicle.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Raise vehicle.
(2) Remove front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Remove front output shaft companion flange.
(4) Remove seal from front case with pry tool (Fig.
93).
INSTALLATION
(1) 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. 94). Once seal is started, continue tap-
ping seal into bore until installer tool seats against
case.
(2) Install companion flange and tighten nut to
122-176 (90-130 ft. lbs.) torque.
(3) Install front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION)
Fig. 92 Fill/Drain Plug and I.D. Tag Location -
Typical
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
Fig. 93 Remove Front Output Shaft Seal
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 94 Front Output Seal Installation
1 - INSTALLER 6952-A
2 - TRANSFER CASE
21 - 310 TRANSFER CASE - NV242WJ
Page 1831 of 2199
REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor (Fig. 97).
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
REAR RETAINER BUSHING
AND SEAL - NV242HD
REMOVAL
(1) Raise vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the rear retainer seal.
(4) Using Remover 6957, remove bushing from
rear retainer (Fig. 98).
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in rear retainer
with fluid port in bushing aligned with slot in
retainer.
(3) Using Installer 8160, drive bushing into
retainer until installer seats against case (Fig. 99).
(4) Using Installer C-3995-A, install seal in rear
retainer (Fig. 100).
Fig. 97 Transfer Case Position Sensor and
Connector
1 - TRANSFER CASE POSITION SENSOR CONNECTOR
2 - TRANSFER CASE POSITION SENSOR
3 - TRANSFER CASE
4 - OUTPUT SPEED SENSOR CONNECTOR
Fig. 98 Rear Retainer Bushing Removal
1 - REMOVER 6957
2 - REAR RETAINER BUSHING
Fig. 99 Rear Retainer Bushing Install
1 - REAR RETAINER BUSHING
2 - INSTALLER 8160
21 - 312 TRANSFER CASE - NV242WJ
POSITION SENSOR (Continued)
Page 1852 of 2199
(12) Clean sealing flanges of front case and rear
case with a wax and grease remover.
(13) Apply 3 mm (1/8 in.) wide bead of Mopart
gasket maker or silicone adhesive sealer to mounting
flange of front case. Work sealer bead around bolt
holes as shown (Fig. 58).
(14) Align and install rear case on front case (Fig.
59).(15) Verify that oil pickup tube is still seated in
case notch and tube end is pointed toward mainshaft
(Fig. 60).
(16) Install case attaching bolts. Alignment bolts
at each end of case are only ones requiring washers
(Fig. 61).
(17) Tighten case bolts to 27-34 N´m (20-25 ft. lbs.)
torque.
Fig. 58 Applying Sealer To Front Case Flange
1 - FRONT CASE FLANGE
2 - SEALER BEAD
Fig. 59 Rear Case Installation
1 - REAR CASE
2 - FRONT CASE
Fig. 60 Checking Position Of Oil Pickup Tube
1 - TUBE O-RING
2 - CORRECT PICKUP TUBE POSITION
Fig. 61 Alignment Bolt
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
WJTRANSFER CASE - NV247 21 - 333
TRANSFER CASE - NV247 (Continued)
Page 1853 of 2199
COMPANION FLANGE AND RANGE LEVER
(1) Install range lever, washer and locknut on sec-
tor shaft (Fig. 62). Tighten locknut to 27-34 N´m
(20-25 ft. lbs.) torque.
(2) Install new seal washer on front output shaft
(Fig. 63).
(3) Lubricate flange hub with transfer case lubri-
cant and install flange on front shaft.
(4) Install new seal washer on front shaft.
(5) Install companion flange and new nut on front
output shaft.
(6) Tighten flange nut to 122-176 N´m (90-130 ft.
lbs.) torque. Use Tool C-3281, or similar tool to hold
flange while tightening yoke nut.
REAR RETAINER AND OIL PUMP
(1) Install new O-ring on flanged end of oil pickup
tube.
(2) Install oil pump (Fig. 64).
(3) Insert oil pickup tube in pump (Fig. 65).(4) Install rear bearing on mainshaft (Fig. 65).
Locating ring groove in bearing goes toward end of
mainshaft.
(5) Install rear bearing retaining snap-ring (Fig.
66).
(6) Install rear bearing locating ring in rear
retainer, if ring was removed during overhaul.
Fig. 62 Range Lever Installation - Typical
1 - RANGE LEVER
2 - WASHER
3 - LOCKNUT
Fig. 63 Flange Seal Washer Installation
1 - YOKE SEAL WASHER
Fig. 64 Installing Oil Pump
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 65 Rear Bearing Installation
1 - REAR BEARING
Fig. 66 Rear Bearing Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING PLIERS
3 - SNAP-RING
21 - 334 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)
Page 1854 of 2199
(7) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to mounting
surface of rear retainer. Allow sealer to set-up
slightly before proceeding.
(8) Slide rear retainer onto mainshaft (Fig. 67).
(9) Spread rear bearing locating ring and slide
rear retainer into place on rear case (Fig. 68).
(10) Install and tighten rear retainer bolts to 27-34
N´m (20-25 ft. lbs.).
(11) Install rubber access plug (Fig. 69).
FINAL ASSEMBLY
(1) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.) torque.(2) Level transfer case and fill it with Mopart
Transfer Case Lubricant. Correct fill level is to bot-
tom edge of fill plug hole.
(3) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.) torque.
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N´m (26 ft. lbs.) torque (Fig. 70).Fig. 67 Rear Retainer Installation
1 - REAR CASE
2 - REAR RETAINER
Fig. 68 Engaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
Fig. 69 Installing Rubber Access Plug
1 - PLUG
Fig. 70 Install Transfer Case
1 - NV247 TRANSFER CASE
WJTRANSFER CASE - NV247 21 - 335
TRANSFER CASE - NV247 (Continued)