Jeep XJ. Manual — part 466
(4) Install drive sprocket snap-ring (Fig. 84).
OIL PUMP AND REAR CASE INSTALLATION
(1) Insert oil pickup tube in oil pump and attach
oil screen and connector hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 85). Be sure screen is seated in case slot as
shown.
(2) Install magnet in front case pocket (Fig. 86).
Fig. 83 Drive Chain And Sprocket Installation
1 – FRONT OUTPUT SHAFT
2 – DRIVE CHAIN
3 – DRIVE SPROCKET
Fig. 84 Drive Sprocket Snap-Ring Installation
1 – DRIVE SPROCKET
2 – DRIVE SPROCKET SNAP RING
Fig. 85 Oil Screen And Pickup Tube Installation
1 – OIL PUMP
2 – OIL SCREEN
3 – CONNECTOR
4 – PICKUP TUBE
Fig. 86 Installing Case Magnet
1 – MAGNET
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
(3) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker or silicone adhesive sealer to seal surface
of front case.
(4) Align and install rear case on front case. Be
sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
(5) Install and tighten front case-to-rear case bolts
to 41 N·m (30 ft. lbs.) torque. Be sure to install a
washer under each bolt used at case dowel
locations.
REAR RETAINER INSTALLATION
(1) Remove rear bearing in retainer using Installer
8128 and Handle C-4171.
(2) Install rear bearing in retainer with Tools
C-4171 and 5064 (Fig. 87).
(3) Install rear bearing O. D. retaining ring with
snap-ring pliers (Fig. 88). Be sure retaining ring is
fully seated in retainer groove.
(4) Apply bead of Mopar
t Sealer P/N 82300234, or
Loctite
y Ultra Gray, to mating surface of rear
retainer. Sealer bead should be a maximum of 3/16
in.
(5) Install rear retainer on rear case. Tighten
retainer bolts to 20–27 N·m (15–20 ft. lbs.) torque.
(6) Install rear bearing I. D. retaining ring and
spacer on output shaft.
(7) Apply liberal quantity of petroleum jelly to new
rear seal and to output shaft. Petroleum jelly is
needed to protect seal lips during installation.
(8) Slide seal onto Seal Protector 6992 (Fig. 89).
Slide seal protector and seal onto output shaft.
(9) Slide Installer C-4076-B onto seal protector
with the recessed side of the tool toward the seal.
Drive seal into rear bearing retainer with Installer
C-4076-B and Handle MD-998323 (Fig. 90).
(10) Install rear slinger with Installer 8408.
(11) Install boot on output shaft slinger and crimp
retaining clamp with tool C-4975-A (Fig. 91).
FRONT YOKE AND SWITCH INSTALLATION
(1) Install indicator switch in front case. Tighten
switch to 20–34 N·m (15–25 ft. lbs.) torque.
(2) Lubricate yoke hub with transmission fluid and
install yoke on front shaft.
(3) Install new seal washer on front shaft.
(4) Install yoke on front shaft. Secure yoke with
new nut.
Fig. 87 Installing Rear Bearing In Retainer
1 – SPECIAL TOOL C-4171
2 – SPECIAL TOOL 5064
3 – REAR RETAINER
Fig. 88 Rear Bearing Retaining Ring Installation
1 – REAR BEARING O. D. RETAINING RING
2 – SNAP RING PLIERS
Fig. 89 Output Shaft Seal and Protector
1 – OUTPUT SHAFT SEAL
2 – SPECIAL TOOL 6992
3 – TRANSFER CASE
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
CLEANING AND INSPECTION
NV242 TRANSFER CASE
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.
MAINSHAFT/SPROCKET/HUB INSPECTION
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 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. 92). 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.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 93). 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. 94). 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 all pur-
pose cleaner. This will ensure proper adhesion of the
sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended. Also replace the boot if cut or torn.
Replace the boot band clamps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 95). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut and seal washer as neither part should be
reused.
Fig. 91 Slinger Boot Installation
1 – SPECIAL TOOL C-4975–A
2 – SLINGER
3 – BOOT
4 – CLAMP
Fig. 90 Rear Seal Installation
1 – SPECIAL TOOL C-4076–B
2 – SPECIAL TOOL MD998323
3 – TRANSFER CASE
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320–400 grit emery
to smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 96).
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. Clean the sealing surfaces with a scraper and all
purpose cleaner. This will ensure proper sealer adhe-
sion at assembly. Replace the input retainer seal; do
not reuse it.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with Loctite
y 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.
Fig. 92 Input Gear And Carrier Components
1 – PLANETARY CARRIER
2 – REAR THRUST WASHER
3 – FRONT THRUST WASHER
4 – CARRIER LOCK RING
5 – CARRIER LOCK RETAINING RING
6 – INPUT GEAR
Fig. 93 Shift forks
1 – RANGE FORK
2 – MODE FORK AND RAIL
3 – MODE SPRING
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NV242 TRANSFER CASE
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CLEANING AND INSPECTION (Continued)
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