Jeep XJ. Manual — part 461
(3) Remove front output shaft yoke.
(4) Remove seal from front case with pry tool (Fig.
8).
INSTALLATION
(1) Install new front output seal in front case with
Installer Tool 6952-A as follows:
(a) Place new seal on tool. Garter spring on seal
goes toward interior of case.
(b) Start seal in bore with light taps from ham-
mer (Fig. 9). Once seal is started, continue tapping
seal into bore until installer tool seats against case.
DISASSEMBLY AND ASSEMBLY
NV242 TRANSFER CASE
DISASSEMBLY
REAR RETAINER REMOVAL
(1) Remove output shaft boot. Spread band clamp
that secures boot on slinger with a suitable awl.
Then slide boot off shaft (Fig. 10).
(2) Using puller MD-998056-A, remove rear slinger
(Fig. 11).
Fig. 8 Remove Front Output Shaft Seal
1 – OUTPUT SHAFT SEAL
2 – PRYBAR
Fig. 9 Front Output Seal Installation
1 – INSTALLER 6952–A
2 – TRANSFER CASE
Fig. 10 Output Boot—Typical
1 – SLINGER
2 – BOOT
3 – AWL
4 – TRANSFER CASE
Fig. 11 Rear Slinger Removal
1 – TRANSFER CASE
2 – SPECIAL TOOL MD998056–A
3 – SLINGER
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NV242 TRANSFER CASE
XJ
REMOVAL AND INSTALLATION (Continued)
(3) Remove rear seal from retainer (Fig. 12). Use
pry tool, or collapse seal with punch to remove it.
(4) Remove rear output bearing I. D. retaining
ring (Fig. 13).
(5) Remove speedometer adapter.
(6) Remove rear retainer bolts.
(7) Remove rear retainer. Tap retainer with mallet
and pry upward to break sealer bead. Then slide
retainer off case and output shaft (Fig. 14).
(8) Remove rear bearing O. D. retaining ring with
snap ring pliers. Then tilt pump and slide it off out-
put shaft (Fig. 15)
(9) Remove pickup tube O-ring from pump (Fig.
16) but do not disassemble pump; it is not a repair-
able part.
(10) Remove seal from oil pump with pry tool.
(11) Remove bolts attaching rear case to front case
(Fig. 17). Note position of the two black finish bolts
Fig. 12 Rear Seal Removal
1 – REAR RETAINER
2 – OUTPUT SHAFT SEAL
Fig. 13 Rear Bearing I. D. Retaining Ring Removal
1 – SNAP RING PLIERS
2 – REAR BEARING I. D. RETAINING RING
Fig. 14 Rear Retainer Removal
1 – MAINSHAFT
2 – REAR RETAINER
Fig. 15 Oil Pump Removal
1 – OIL PUMP
Fig. 16 Pickup Tube O-Ring Location
1 – OIL PUMP
2 – O-RING
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NV242 TRANSFER CASE
21 - 381
DISASSEMBLY AND ASSEMBLY (Continued)
at each end of the case. These bolts go through the
case dowels and require a washer under the bolt
head.
(12) Remove rear case from front case (Fig. 18).
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.
(13) Remove oil pickup tube and screen from rear
case (Fig. 19).
YOKE AND RANGE LEVER REMOVAL
(1) Remove front yoke nut:
(a) Move range lever to 4L position.
(b) Remove nut with socket and impact wrench
(Fig. 20).
(2) Remove yoke. If yoke is difficult to remove by
hand, remove it with bearing splitter, or with stan-
dard two jaw puller (Fig. 21). Be sure puller tool is
positioned on yoke and not on slinger as slinger will
be damaged.
Fig. 17 Spline And Dowel Bolt Locations
1 – DOWEL BOLT AND WASHER (2)
2 – CASE BOLT (5)
3 – SPLINE HEAD BOLT (1)
Fig. 18 Loosening/Removing Rear case
1 – MAINSHAFT
2 – SCREWDRIVER
3 – FRONT CASE
4 – SCREWDRIVER
5 – REAR CASE
Fig. 19 Oil Pickup Screen, Hose And Tube Removal
1 – CONNECTING HOSE
2 – PICKUP SCREEN
3 – PICKUP TUBE
Fig. 20 Yoke Nut Removal
1 – IMPACT WRENCH
2 – SOCKET
3 – YOKE
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NV242 TRANSFER CASE
XJ
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(4) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 22).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(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 REMOVAL AND
DISASSEMBLY
(1) Remove shift detent plug, spring and pin (Fig.
26).
(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.
Fig. 21 Yoke Removal
1 – PULLER TOOL
2 – YOKE
Fig. 22 Range Lever Removal
1 – RANGE LEVER
2 – SECTOR SHAFT
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
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NV242 TRANSFER CASE
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DISASSEMBLY AND ASSEMBLY (Continued)
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