JEEP XJ 1995 Service And Repair Manual

SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig. 3).
4) Verify that linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully en-
gaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
(8) Verify proper shift operation.
SHIFT LEVER REMOVAL (XJ)
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 4). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to park brake section in
Group 5 for procedures.
(6) Remove screws attaching lever assembly to floor-
pan and remove assembly and shift rod (if left attached).
SHIFT LEVER INSTALLATION (XJ)
(1) If shift rod was not removed from lever assem-
bly, work rod down through floorpan opening. Then
position lever assembly on floorpan and install as-
sembly attaching screws.
(2) Install console.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever.
(5) Tighten trunnion lock bolt.
(6) Lower vehicle.
(7) Lower vehicle.
(8) Remove shift lever spacer and install bezel.
SPEEDOMETER SERVICE
Speedometer service procedures are covered in the
automatic transmission sections within Group 21.
Refer to these sections when necessary.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Place support stand under transmission.
(6) Remove rear crossmember.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and re-
move sensor and adapter assembly if necessary.
(9) Disconnect shift rod from transfer case range
lever.
(10) Disconnect transfer case vent hoses and elec-
trical switch connector.
(11) Support transfer case with transmission jack.
(12) Remove bolts attaching transfer case to trans-
mission.
(13) Secure transfer case to jack with chains.
(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
(16) If transfer case was removed for overhaul, re-
move damper from rear retainer.
TRANSFER CASE INSTALLATION
(1) Install damper on transfer case rear retainer, if
equipped (Fig. 4). Tighten damper attaching nuts to
54 Nzm (40 ft. lbs.) torque.
(2) Mount transfer case on transmission jack. Se-
cure transfer case to jack with safety chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts and
slide transfer case onto transmission.
(5) Install and tighten transfer case attaching nuts
to 35 Nzm (26 ft. lbs.) torque.
Fig. 3 Shift Linkage (XJ)
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(6) Install vehicle speed sensor and adapter, if re-
moved. Then connect vehicle speed sensor wires, vent
hoses and electrical switch connector.
(7) Align and connect propeller shafts. Tighten
shaft U-joint clamp bolts to 19 Nzm (14 ft. lbs.)
torque.
(8) Fill transfer case with Mopar Dexron II. Cor-
rect fill level is to bottom edge of fill plug hole.
(9) Install rear crossmember. Tighten crossmember
bolts to 41 Nzm (30 ft. lbs.) torque.
(10) Remove transmission jack and transmission
support stand.
(11) Move transfer case range lever to 4L position.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage as described
in this section.
(14) Lower vehicle.
TRANSFER CASE DISASSEMBLY AND OVERHAUL
(1) Remove fill and drain plugs.
(2) Remove front yoke. Discard yoke seal washer
and nut.
(3) Place transfer case range lever in 4L position.
(4) Remove extension housing attaching bolts.
(5) Tap extension housing in a clockwise direction
to break sealer bead and remove housing (Fig. 1).
CAUTION: To avoid damaging the sealing surfaces
of the extension housing and rear retainer, do not
attempt to pry or wedge the housing off the re-
tainer.
(6) Remove rear bearing snap ring from mainshaft
(Fig. 2). Discard snap ring.
(7) Remove rear retainer attaching bolts.
(8) Loosen rear retainer (Fig. 3). Position long
screwdriver under each tab at ends of retainer hous-
ing and pry retainer upward.CAUTION: Do not pry against the sealing surfaces
of the retainer or rear case. The surfaces could be
damaged.
(9) Lift rear retainer up and off case and main-
shaft (Fig. 4).
(10) Remove bolts attaching rear case to front case.
Retain bolts and the washers.
(11) Loosen rear case with two screwdrivers (Fig.
5). Insert screwdrivers into slots cast in case ends.
Then gently pry upward to break sealer bead.
Fig. 4 Damper Mounting
Fig. 1 Extension Housing Removal
Fig. 2 Removing Rear Bearing Snap Ring
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CAUTION: Do not pry against the sealing surfaces
of the front case or rear case. The surfaces could
be damaged.
(12) Remove rear case and oil pump as assembly
(Fig. 6).
Fig. 3 Loosening Rear Retainer
Fig. 4 Rear Retainer Removal
Fig. 5 Loosening Rear Case
Fig. 6 Rear Case And Oil Pump Removal
JNP242 TRANSFER CASE 21 - 311

(13) Slide oil screen (Fig. 7) out of case pocket.
(14) Remove oil pump, pickup tube and oil screen
from rear case (Fig. 8).
(15) Remove pickup tube and screen from pump.
Do not disassemble oil pump; it is not repair-
able. Pumps are serviced only as an assembly.(16) Remove pickup tube O-ring from oil pump
(Fig. 9).
(17) Remove and discard oil pump seal.
(18) Remove magnet from front case.
(19) Remove drive sprocket snap ring (Fig. 10).
Fig. 7 Unseating Oil Screen
Fig. 8 Oil Pump/Pickup Tube/Screen Removal
Fig. 9 Pickup Tube O-Ring Removal
Fig. 10 Drive Sprocket Snap Ring Removal
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(20) Remove drive sprocket and chain (Fig. 11).
(21) Remove front output shaft (Fig. 12).(22) Remove transfer case shift lever nut and lever.
(23) Remove shift detent plug, spring and pin (Fig.
13)
(24) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole (Fig. 14).
(25) Remove range fork lockpin with size number
one easy-out tool. Grip easy-out tool with locking pli-
ers and remove pin with counterclockwise, twist and
pull motion (Fig. 14).
fig. 11 Drive Sprocket And Chain Removal
Fig. 12 Removing Front Output Shaft
Fig. 13 Detent Component Removal
Fig. 14 Low Range Fork Lockpin Removal
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(26) Remove shift rail by pulling it straight up and
out of fork (Fig. 15).
(27) Remove mode fork and mainshaft as assembly
(Fig. 16).
(28) Remove mode shift sleeve and mode fork as-
sembly from mainshaft (Fig. 17). Note position of
mode sleeve in fork and remove sleeve.
(29) Remove intermediate clutch shaft snap ring
(Fig. 18).
Fig. 15 Shift Rail Removal
Fig. 16 Mode Fork And Mainshaft Removal
Fig. 17 Mode Fork And Sleeve Removal
Fig. 18 Intermediate Clutch Shaft Snap Ring
Removal
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(30) Remove clutch shaft thrust ring (Fig. 19).
(31) Remove intermediate clutch shaft (Fig. 20).(32) Remove differential snap ring (Fig. 21).
(33) Remove differential (Fig. 22).
(34) Remove differential needle bearings and both
needle bearing thrust washers from mainshaft.
Fig. 19 Clutch Shaft Thrust Ring Removal
Fig. 20 Intermediate Clutch Shaft Removal
Fig. 21 Differential Snap Ring Removal
Fig. 22 Differential Removal
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(35) Slide low range fork pin out of shift sector slot
(Fig. 23)
(36) Remove low range fork and hub (Fig. 24).(37) Remove shift sector (Fig. 25).
(38) Remove shift sector bushing and O-ring (Fig.
26).
Fig. 23 Disengaging Low Range Fork
Fig. 24 Low Range Fork And Hub Removal
Fig. 25 Shift Sector Position
Fig. 26 Sector Bushing And O-Ring Removal
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(39) Remove front bearing retainer bolts.
(40) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 27). Position
screwdriver in slots cast into retainer.
(41) Remove input gear snap ring (Fig. 28).(42) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 29).
(43) Remove low range gear snap ring (Fig. 30).
Fig. 27 Front Bearing Retainer Removal
Fig. 28 Input Gear Snap Ring Removal
Fig. 29 Input And Low Range Gear Assembly
Removal
Fig. 30 Low Range Gear Snap Ring Removal/
Installation
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(44) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 31).
(45) Inspect low range annulus gear (Fig. 32).
Gear is not a serviceable component. If dam-
aged, replace gear and front case as assembly.
(46) Remove oil seals from following components:
²rear retainer
²extension housing
²oil pump
²case halves
(47) Mark differential case halves for reference.
(48) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 33).
(49) Remove thrust washers and planet gears from
case pins (Fig. 34).(50) Remove mainshaft and sprocket gears from
bottom case (Fig. 35). Note gear position for reference
before separating them.
OVERHAUL CLEANING AND INSPECTION
Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
case and retainer seal surfaces.
Clean the oil pickup screen with solvent and allow
it to air dry. Use compressed air to remove solvent
residue from all oil feed passages and channels in
case halves.
Fig. 31 Low Range Gear Disassembly
Fig. 32 Inspecting Low Range Annulus Gear
Fig. 33 Separating Differential Case Halves
Fig. 34 Planet Gears And Thrust Washer Removal
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