JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual

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. 3).
(7) Disconnect front/rear propeller shafts at trans-
fer case. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 4) and
transfer case position sensor.
(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.
(14) Remove transfer case from under vehicle.
DISASSEMBLY
REAR RETAINER - NV242LD
(1) Remove output shaft boot. Spread band clamp
that secures boot on slinger with a suitable awl.
Then slide boot off shaft (Fig. 5).
Fig. 3 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 4 Transfer Case Mounting
1 - NV242 TRANSFER CASE
Fig. 5 Output Boot - Typical
1 - SLINGER
2 - BOOT
3-AWL
4 - TRANSFER CASE
21 - 282 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(2) Using puller MD-998056-A, remove rear slinger
(Fig. 6).
(3) Remove rear seal from retainer (Fig. 7). Use
pry tool, or collapse seal with punch to remove it.(4) Remove rear output bearing I.D. retaining ring
(Fig. 8).
(5) Remove rear retainer bolts.
(6) Remove rear retainer. Tap retainer with mallet
and pry upward to break sealer bead. Then slide
retainer off case and output shaft (Fig. 9).
Fig. 6 Rear Slinger Removal
1 - TRANSFER CASE
2 - SPECIAL TOOL MD998056-A
3 - SLINGER
Fig. 7 Rear Retainer Seal
1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL
Fig. 8 Output Shaft Rear Bearing Retaining Ring
1 - SNAP-RING PLIERS
2 - RETAINING RING
Fig. 9 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
WJTRANSFER CASE - NV242 21 - 283
TRANSFER CASE - NV242 (Continued)

REAR RETAINER - NV242HD
(1) Remove extension housing bolts.
(2) Tap extension housing with plastic or rawhide
mallet to loosen sealer (Fig. 10).
(3) Separate extension housing from rear retainer.
(4) Remove rear bearing snap-ring (Fig. 11).
(5) Remove bolts holding rear retainer to rear case
half.
(6) Loosen rear retainer with pry tool to break
sealer bead. Pry only against retainer boss as shown
(Fig. 12).
(7) Slide retainer off case and output shaft (Fig.
13).
OIL PUMP AND REAR CASE HALF
(1) Remove rear bearing O.D. retaining ring with
snap ring pliers. Then tilt pump and slide it off out-
put shaft (Fig. 14)
(2) Remove pickup tube O-ring from pump (Fig.
15) but do not disassemble pump; it is not a repair-
able part.
(3) Remove seal from oil pump with pry tool.
(4) Remove bolts attaching rear case to front case
(Fig. 16). Note position of the two black finish bolts
at each end of the case. These bolts go through the
case dowels and require a washer under the bolt
head.
Fig. 10 Remove Extension Housing
1 - EXTENSION HOUSING
2 - PLASTIC HAMMER
3 - REAR RETAINER
Fig. 11 Remove the Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
Fig. 12 Loosening Rear Retainer
1 - REAR RETAINER
2-TAB(2)
3 - SCREWDRIVER
4-TAB
Fig. 13 Rear Retainer Removal
1 - MAINSHAFT
2 - REAR RETAINER
21 - 284 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(5) Remove rear case from front case (Fig. 17).
Insert screwdrivers into slots cast into each end of
case. Then pry upward to break sealer bead and
remove rear case.
CAUTION: Do not pry on the sealing surface of
either case half as the surfaces will become dam-
aged.
(6) Remove oil pickup tube and screen from rear
case (Fig. 18).
Fig. 14 Oil Pump Removal
1 - OIL PUMP
Fig. 15 Pickup Tube O-Ring Location
1 - OIL PUMP
2 - O-RING
Fig. 16 Spline And Dowel Bolt Locations
1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLTS
3 - SPLINE HEAD BOLT (1)
Fig. 17 Loosening/Removing Rear Case
1 - MAINSHAFT
2 - SCREWDRIVER
3 - FRONT CASE
4 - SCREWDRIVER
5 - REAR CASE
Fig. 18 Oil Pickup Screen, Hose And Tube Removal
1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE
WJTRANSFER CASE - NV242 21 - 285
TRANSFER CASE - NV242 (Continued)

COMPANION FLANGE AND RANGE LEVER
(1) Remove transfer case position sensor (Fig. 19).
(2) Install two bolts (Fig. 20) partially into the pro-
pellor shaft companion flange, 180É from each other.
(3) Install the rectangular end of the Flange
Holder C-3281 over the bolts to hold the companion
flange stationary and remove the nut holding the
companion flange to the output shaft.
(4) Use Remover C-452 (Fig. 21) to remove the
companion flange.(5) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(6) Remove the bolt (Fig. 22) that attaches the
range lever to sector shaft. Then move sector to neu-
tral position and remove range lever from shaft.
NOTE: Be sure to note the orientation of the range
lever (lever up or down) so that it may be re-in-
stalled in the same direction.
Fig. 19 Remove Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 20 Hold Companion Flange - Typical
1 - HOLDER C-3281
2 - BOLTS
3 - COMPANION FLANGE
Fig. 21 Remove Companion Flange - Typical
1 - TRANSFER CASE
2 - COMPANION FLANGE
3 - REMOVER C-452
Fig. 22 Remove Shift Lever Bolt - Typical
1 - RANGE LEVER
2 - RANGE LEVER BOLT
3 - TRANSFER CASE
21 - 286 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove drive sprocket snap-ring (Fig. 23).
(2) Remove drive sprocket and chain (Fig. 24).
(3) Remove front output shaft (Fig. 25).
SHIFT FORKS AND MAINSHAFT
(1) Remove shift detent plug, spring and pin (Fig.
26).
Fig. 23 Drive Sprocket Snap-Ring Removal
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 24 Drive Sprocket And Chain Removal
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
Fig. 25 Removing Front Output Shaft
1 - FRONT OUTPUT SHAFT
Fig. 26 Detent Component Removal
1 - PLUNGER
2 - O-RING
3 - PLUG
4 - SPRING
WJTRANSFER CASE - NV242 21 - 287
TRANSFER CASE - NV242 (Continued)

(2) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole.
(3) Remove range fork lockpin with size number
one easy-out tool as follows:
(a) Insert easy-out tool through access hole in
side of transfer case and into lock-pin.
(b) Tap easy-out tool into lock-pin with hammer
until tool is securely engaged into the lock-pin.
(c) Install a t-handle, such as from a tap and die
set, onto the easy-out tool.
(d) Securely tighten the t-handle onto the tool.
(e) In one motion, pull upward and turn the
t-handle counter-clockwise to remove the lock-pin.
(4) Remove shift rail by pulling it straight up and
out of fork (Fig. 27).
(5) Remove mode fork and mainshaft as assembly
(Fig. 28).
(6) Remove mode shift sleeve and mode fork
assembly from mainshaft (Fig. 29). Note position of
mode sleeve in fork and remove sleeve.
Fig. 27 Shift Rail Removal
1 - SHIFT RAIL
2 - MODE FORK
Fig. 28 Mainshaft And Mode Fork Removal
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 29 Separate Mode Fork And Sleeve
1 - MAINSHAFT
2 - MODE SLEEVE
3 - MODE FORK ASSEMBLY
21 - 288 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(7) Remove intermediate clutch shaft snap-ring
(Fig. 30).
(8) Remove clutch shaft thrust ring (Fig. 31).
(9) Remove intermediate clutch shaft (Fig. 32).
(10) Remove differential snap-ring (Fig. 33).
(11) Remove differential (Fig. 34).
(12) Remove differential needle bearings and both
needle bearing thrust washers from mainshaft.
Fig. 30 Intermediate Clutch Shaft Snap-Ring
Removal
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
Fig. 31 Clutch Shaft Thrust Ring Removal
1 - CLUTCH SHAFT THRUST RING
Fig. 32 Intermediate Clutch Shaft Removal
1 - INTERMEDIATE CLUTCH SHAFT
Fig. 33 Differential Snap-Ring Removal
1 - DIFFERENTIAL SNAP-RING
WJTRANSFER CASE - NV242 21 - 289
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)

(4) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 39).
(5) Remove low range gear snap-ring (Fig. 40).
(6) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 41).
Fig. 38 Input Gear Snap Ring Removal
1 - INPUT GEAR
2 - SNAP-RING
Fig. 39 Input And Low Range Gear Assembly
Removal
1 - INPUT-LOW RANGE GEARS
2 - SPECIAL TOOL 7829-A
3 - SPECIAL TOOL C-4171
Fig. 40 Remove Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
Fig. 41 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
WJTRANSFER CASE - NV242 21 - 291
TRANSFER CASE - NV242 (Continued)