nv242 JEEP GRAND CHEROKEE 2003 WJ / 2.G User Guide

(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)

(7) Inspect low range annulus gear (Fig. 42).Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oil seals from following components:
²front bearing retainer.
²rear retainer.
²oil pump.
²case halves.
DIFFERENTIAL
(1) Mark differential case halves for reference.
(2) Remove differential case bolts.
(3) Invert differential on workbench.
(4) Separate top case from bottom case. Use slots
in case halves to pry them apart (Fig. 43).
(5) Remove thrust washers and planet gears from
case pins (Fig. 44).
(6) Remove mainshaft and sprocket gears from
bottom case (Fig. 45). Note gear position for reference
before separating them.
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and all
purpose cleaner. Use compressed air to remove sol-
vent residue from oil feed passages in the case
halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
Fig. 42 Inspecting Low Range Annulus Gear
1 - LOW RANGE ANNULUS GEAR
Fig. 43 Separating Differential Case Halves
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig. 44 Planet Gears And Thrust Washer Removal
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
21 - 292 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 46). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
Fig. 46 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 45 Mainshaft And Sprocket Gear Removal
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
WJTRANSFER CASE - NV242 21 - 293
TRANSFER CASE - NV242 (Continued)

SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 47). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads. The mode fork
pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
Inspect the retainer components (Fig. 48). Replace
the bearing if rough or noisy. Check the retainer for
cracks or wear in the bearing bore. Clean the
retainer sealing surfaces with a scraper and 3M all
purpose cleaner. This will ensure proper adhesion of
the sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Replace any part if distorted, bent, or broken. Also
replace the boot if cut or torn. Replace the boot band
clamps, do not reuse them.
Fig. 48 Rear Retainer - Typical
1 - REAR RETAINER 5 - BAND CLAMPS
2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER
3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING
4 - BOOT 8 - REAR BEARING
Fig. 47 Shift Fork And Wear Pad Locations
1 - MODE FORK
2 - RANGE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
21 - 294 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)