Jeep XJ. Manual — part 459
Check the front case mounting studs and vent
tube. The tube can be secured with Loctite 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoil stainless
steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT
(1) Shift transfer case into 4L position.
(2) Raise vehicle.
(3) Loosen lock bolt on adjusting trunnion (Fig.
87).
(4) Be sure linkage rod slides freely in trunnion.
Clean rod and apply spray lube if necessary.
(5) Verify that transfer case range lever is fully
engaged in 4L position.
(6) Tighten adjusting trunnion lock bolt.
(7) Lower vehicle.
Fig. 85 Seal Contact Surface Of Yoke Slinger
1 – FRONT SLINGER (PART OF YOKE)
2 – SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 86 Low Range Annulus Gear
1 – FRONT CASE
2 – LOW RANGE ANNULUS GEAR
Fig. 87 Shift Linkage
1 – TRANSFER CASE SHIFT LEVER SHAFT
2 – SEAL
3 – TRANSFER CASE SHIFT LEVER ASSEMBLY
4 – FLOORPAN
5 – TRUNNION LOCK BOLT
6 – SHIFT ROD
7 – ADJUSTING TRUNNION
8 – TORQUE SHAFT BRACKET
9 – RANGE LEVER
10 – TORQUE SHAFT ROD
11 – TORQUE SHAFT
12 – LINKAGE BRACKET
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NV231 TRANSFER CASE
XJ
CLEANING AND INSPECTION (Continued)
SPECIFICATIONS
TORQUE
DESCRIPTION
TORQUE
Plug, Detent . . . . . . . . . . 16–24 N·m (12–18 ft. lbs.)
Plug, Drain/Fill . . . . . . . 20–34 N·m (15–25 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Front Brg. Retainer . . . . . 21 N·m (16 ft. lbs.)
Bolt, Case Half . . . . . . . . 27–34 N·m (20–25 ft. lbs.)
Nut, Front Yoke . . . . 122–176 N·m (90–130 ft. lbs.)
Nut, Range Lever . . . . . . 27–34 N·m (20–25 ft. lbs.)
Bolt, Rear Retainer . . . . 35–46 N·m (26–34 ft. lbs.)
Nuts, Mounting . . . . . . . 35–47 N·m (26–35 ft. lbs.)
Switch, Indicator . . . . . . 20–34 N·m (15–25 ft. lbs.)
SPECIAL TOOLS
NV231
Installer—C-4076-B
Puller, Slinger—MD-998056–A
Installer—MD-998323
Seal Protector—6992
Installer, Boot Clamp—C-4975-A
Installer, Seal—8143
Handle, Universal—C-4171
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NV231 TRANSFER CASE
21 - 373
Installer, Seal—C-4210
Installer, Bearing—5064
Installer, Bearing—5065
Installer, Bushing—5066
Installer, Bearing—8128
Remover—L-4454
Cup—8148
Installer, Seal—7884
Installer, Pump Housing Seal—7888
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NV231 TRANSFER CASE
XJ
SPECIAL TOOLS (Continued)
NV242 TRANSFER CASE
TABLE OF CONTENTS
page
page
DESCRIPTION AND OPERATION
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 375
LUBRICANT AND FILL LEVEL . . . . . . . . . . . . . . 376
DIAGNOSIS AND TESTING
NV242 DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 376
REMOVAL AND INSTALLATION
TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . . 377
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 377
SPEEDOMETER. . . . . . . . . . . . . . . . . . . . . . . . . 378
FRONT OUTPUT SHAFT SEAL . . . . . . . . . . . . . 379
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 380
CLEANING AND INSPECTION
NV242 TRANSFER CASE. . . . . . . . . . . . . . . . . . 402
ADJUSTMENTS
SHIFT LINKAGE ADJUSTMENT . . . . . . . . . . . . . 405
SPECIFICATIONS
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
SPECIAL TOOLS
NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
DESCRIPTION AND OPERATION
NV242 TRANSFER CASE
DESCRIPTION
The NV242 is a full-time transfer case (Fig. 1). It
provides full time 2-wheel, or 4-wheel drive opera-
tion.
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 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.
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
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.
Fig. 1 NV242 Transfer Case
Fig. 2 Fill/Drain Plug And I. D. Tag Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
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NV242 TRANSFER CASE
21 - 375
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