gear shift JEEP GRAND CHEROKEE 2003 WJ / 2.G Owners Manual

(8) Position the accumulator cover onto the valve
body.
(9) Install the screws to hold the accumulator
cover onto the valve body. Tighten the screws to 4.5
N´m (40 in. lbs.).
(10) Install the TRS selector plate onto the valve
body and the manual valve.
(11) Install the solenoid and pressure switch
assembly onto the valve body.
(12) Install the screws to hold the solenoid and
pressure switch assembly onto the valve body.
Tighten the screws to 5.7 N´m (50 in. lbs.). Tighten
the screws adjacent to the arrows cast into the bot-
tom of the transfer plate first.
(13) Position the detent spring onto the valve body.
(14) Install the screw to hold the detent spring
onto the valve body. Tighten the screw to 4.5 N´m (40
in. lbs.).
(15) Install new clutch passage seals onto the
valve body, if necessary
INSTALLATION
(1) Check condition of seals on valve body and the
solenoid and pressure switch assembly. Replace seals
if cut or worn.
(2) Place TRS selector plate in the PARK position.
(3) Place the transmission in the PARK position.
(4) Lubricate seal on the solenoid and pressure
switch assembly connector with petroleum jelly.(5) Position valve body in transmission and align
the manual lever on the valve body to the pin on the
transmission manual shift lever.
(6) Seat valve body in case and install one or two
bolts to hold valve body in place.
(7) Tighten valve body bolts alternately and evenly
to 12 N´m (105 in. lbs.) torque.
(8) Install a new primary oil filter seal in the oil
pump inlet bore. Seat the seal in the bore with the
butt end of a hammer, or other suitable tool.
CAUTION: The primary oil filter seal MUST be fully
installed flush against the oil pump body. DO NOT
install the seal onto the filter neck and attempt to
install the filter and seal as an assembly. Damage to
the transmission will result.
(9) Place replacement filter in position on valve
body and into the oil pump.
(10) Install screw to hold filter to valve body.
Tighten screw to 4.5 N´m (40 in. lbs.) torque.
(11) Connect the solenoid and pressure switch
assembly connector.
(12) Install oil pan. Tighten pan bolts to 12 N´m
(105 in. lbs.) torque.
(13) Lower vehicle and fill transmission with
MopartATF +4, type 9602, fluid.
(14) Check and adjust gearshift cable, if necessary.
WJAUTOMATIC TRANSMISSION - 545RFE 21 - 279
VALVE BODY (Continued)

TRANSFER CASE - NV242
TABLE OF CONTENTS
page page
TRANSFER CASE - NV242
DESCRIPTION........................280
OPERATION..........................281
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV242.......................281
REMOVAL............................282
DISASSEMBLY........................282
CLEANING...........................292
INSPECTION.........................293
ASSEMBLY...........................295
INSTALLATION........................307
SPECIFICATIONS
TRANSFER CASE - NV242.............308
SPECIAL TOOLS
TRANSFER CASE - NV242.............308
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................310FRONT OUTPUT SHAFT SEAL
REMOVAL............................310
INSTALLATION........................310
POSITION SENSOR
DESCRIPTION........................311
OPERATION..........................311
REMOVAL............................312
INSTALLATION........................312
REAR RETAINER BUSHING AND SEAL -
NV242HD
REMOVAL............................312
INSTALLATION........................312
SHIFT CABLE
REMOVAL............................313
INSTALLATION........................313
TRANSFER CASE - NV242
DESCRIPTION
The NV242 is a full transfer case (Fig. 1). It pro-
vides full time 2-wheel, or 4-wheel drive operation.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
TRANSFER CASE IDENTIFICATION
Two versions of the NV242 are used in the WJ
vehicles, NV242LD and NV242HD. The two transfer
cases can be distinguished from one another by the
rear output shaft retainer. The NV242LD uses a rub-
ber boot to cover the rear output shaft, while the
NV242HD uses a cast aluminum housing. Other than
this difference, the two transfer cases are serviced
the same.
A circular ID tag is attached to the rear case of
each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.The transfer case serial number also represents
the date of build.
SHIFT MECHANISM
Operating ranges are selected with a lever in the
floor mounted shifter assembly. The shift lever is con-
nected to the transfer case range lever by an adjust-
able cable. A straight line shift pattern is used.
Range positions are marked on the shifter bezel.
Fig. 1 NV242 Transfer Case
21 - 280 TRANSFER CASE - NV242WJ

OPERATION
The input gear is splined to the transmission out-
put shaft. It drives the mainshaft through the plan-
etary gear and range hub. The front output shaft is
operated by a drive chain that connects the shaft to a
drive sprocket on the mainshaft. The drive sprocket
is engaged/disengaged by the mode fork, which oper-
ates the mode sleeve and hub. The sleeve and hub
are not equipped with a synchro mechanism for shift-
ing.
OPERATING RANGES
NV242 operating ranges are 2WD (2-wheel drive),
4x4 part-time, 4x4 full time, and 4 Lo.
The 2WD and 4x4 full time ranges can be used at
any time and on any road surface.
The 4x4 part-time and 4 Lo ranges are for off road
use only. The only time these ranges can be used on
hard surface roads, is when the surface is covered
with snow and ice.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV242
DIAGNOSIS CHART
CONDITION POSSIBLE CAUSE CORRECTION
Transfer case difficult to shift or will
not shift into desired range.1) Transfer case shift linkage
binding.1) Repair or replace linkage as
necessary.
2) Insufficient or incorrect lubricant. 2) Drain and refill transfer case with
the correct type and quantity of
lubricant.
3) Internal transfer case
components binding, worn, or
damaged.3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.1) Insufficient or incorrect lubricant. 1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Lubricant leaking from transfer case
seals or vent.1) Transfer case overfilled. 1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.3) Replace suspect seal.
Transfer case will not shift through
4X4 part time range (light remains
on)1) Incomplete shift due to drivetrain
torque load.1) Momentarily release the
accelerator pedal to complete the
shift.
2) Incorrect tire pressure. 2) Correct tire pressure as
necessary.
3) Excessive Tire wear. 3) Correct tire condition as
necessary.
4) Excessive vehicle loading. 4) Correct as necessary.
Fig. 2 Fill/Drain Plug And I.D. Tag Locations
1 - I.D. TAG
2 - FILL PLUG
3 - DRAIN PLUG
WJTRANSFER CASE - NV242 21 - 281
TRANSFER CASE - NV242 (Continued)

(13) Slide low range fork pin out of shift sector
slot.
(14) Remove low range fork and sleeve (Fig. 35).
(15) Remove shift sector.(16) Remove the shift sector shaft bushing and
o-ring (Fig. 36).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Remove front bearing retainer bolts.
(2) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 37). Position
screwdriver in slots cast into retainer.
(3) Remove input gear snap-ring (Fig. 38).
Fig. 34 Differential Removal
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 35 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 36 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 37 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
21 - 290 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(5) Align and position differential top case on bot-
tom case (Fig. 67). Align using scribe marks made at
disassembly.
(6) While holding differential case halves together,
invert the differential and start the differential case
bolts.
(7) Tighten differential case bolts to specified
torque.
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 68).
(2) Install low range gear snap ring (Fig. 69).
(3) Lubricate input gear and low range gears with
automatic transmission fluid.
(4) Start input gear shaft into front case bearing.
(5) Press input gear shaft into front bearing.
(6) Install new input gear snap ring (Fig. 70).
(7) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to seal surface
of front bearing retainer.
(8) Install front bearing retainer (Fig. 71). Tighten
retainer bolts to 16 ft. lbs. (21 N´m) torque.
SHIFT FORKS, SECTOR, AND MAINSHAFT
(1) Install the shift sector shaft o-ring and bush-
ing.
(2) Install shift sector.(3) Install new pads on low range fork, if neces-
sary.
(4) Assemble low range fork and sleeve.
Fig. 67 Differential Case Assembly
1 - TOP CASE
2 - BOTTOM CASE
3 - CASE ALIGNMENT MARKS
Fig. 68 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 69 Install Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
21 - 300 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(5)Position low range fork and sleeve in case. Be
sure low range fork pin is engaged in shift sector slot.
(6) Install first mainshaft bearing spacer on main-
shaft (Fig. 72).
(7) Install bearing rollers on mainshaft (Fig. 72).
Coat bearing rollers with generous quantity of petro-
leum jelly to hold them in place.
(8) Install remaining bearing spacer on mainshaft
(Fig. 72). Do not displace any bearings while install-
ing spacer.(9) Install differential (Fig. 73). Do not displace
mainshaft bearings when installing differential.
Fig. 70 Input Gear Snap-Ring Installation
1 - INPUT GEAR
2 - SNAP-RING
Fig. 71 Installing Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 72 Installing Mainshaft Bearing Rollers and
Spacers
1 - MAINSHAFT BEARING ROLLERS
2 - BEARING SPACERS
Fig. 73 Differential Installation
1 - DIFFERENTIAL
2 - MAINSHAFT
WJTRANSFER CASE - NV242 21 - 301
TRANSFER CASE - NV242 (Continued)

(15) Install mode sleeve in mode fork (Fig. 79).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(16) Install mode fork and mainshaft assembly in
case (Fig. 80). Rotate mainshaft slightly to engage
shaft with low range gears.
(17) Rotate mode fork pin into shift sector slot.Fig. 79 Installing Mode Fork And Sleeve
1 - MAINSHAFT
2 - MODE SLEEVE
3 - MODE FORK ASSEMBLY
Fig. 80 Assembled Mainshaft And Mode Fork
Installation
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 78 Mode Fork Assembly Inspection
1 - SLIDER
2 - MODE FORK
3 - BUSHING/SPRING
4 - TUBE
5-PADS
WJTRANSFER CASE - NV242 21 - 303
TRANSFER CASE - NV242 (Continued)

TRANSFER CASE - NV247
TABLE OF CONTENTS
page page
TRANSFER CASE - NV247
DESCRIPTION........................315
OPERATION..........................316
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV247.......................316
REMOVAL............................317
DISASSEMBLY........................317
CLEANING...........................324
INSPECTION.........................324
ASSEMBLY...........................326
INSTALLATION........................335
SPECIFICATIONS
TRANSFER CASE - NV247.............336
SPECIAL TOOLS
TRANSFER CASE - NV247.............337FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................338
FRONT OUTPUT SHAFT SEAL
REMOVAL............................338
INSTALLATION........................338
REAR RETAINER BUSHING AND SEAL
REMOVAL............................339
INSTALLATION........................339
SHIFT CABLE
REMOVAL............................340
INSTALLATION........................340
TRANSFER CASE - NV247
DESCRIPTION
The NV247 (Fig. 1) is an on-demand 4-wheel drive
transfer case with two operating ranges and a neu-
tral position. Operating ranges are 4-high and 4-low.
The 4-low range is used for extra pulling power in
off-road situations.
TRANSFER CASE IDENTIFICATION
A circular I.D. tag is attached to the rear case of
each NV247 transfer case (Fig. 2). The tag indicates
the following information:
²Model number
²Serial number
²Assembly number
²Gear ratio
²Location of manufacture
The transfer case serial number also represents
the date of build.
Fig. 1 NV247 Transfer Case
Fig. 2 Transfer Case I.D. Tag
1 - FILL PLUG
2 - I.D. TAG
3 - DRAIN PLUG
WJTRANSFER CASE - NV247 21 - 315

CONDITION POSSIBLE CAUSE CORRECTION
NOISY INÐOR JUMPS OUT OF
4WD LOW RANGE1. Transfer case not completely
engaged in 4WD LOW (possibly
from shift to 4L while rolling)1. Stop vehicle, shift transfer case
to neutral, then shift back to 4WD
LOW
2. Shift linkage loose, binding, or is
misadjusted2. Tighten, lubricate, or repair
linkage as necessary. Adjust linkage
if necessary
3. Range fork cracked, inserts
worn, or fork is binding on shift rail3. Disassemble unit and repair as
necessary
4. Annulus gear or lockplate worn
or damaged4. Disassemble unit and repair as
necessary
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR FROM
VENT1. Transfer case over filled 1. Drain to correct level
2. Vent closed or restricted 2. Clear or replace vent if necessary
3. Output shaft seals damaged or
installed correctly3. Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove transfer case drain plug and drain
transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped (Fig. 4).
(7) Disconnect front propeller shaft from transfer
case at companion flange. Remove rear propeller
shaft from vehicle. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
CAUTION: Do not allow propshafts to hang at
attached end. Damage to joint can result.
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 5).
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Pull transfer case and jack rearward to disen-
gage transfer case (Fig. 5).
(14) Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
Fig. 4 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
WJTRANSFER CASE - NV247 21 - 317
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)