Jeep XJ. Manual — part 460
OPERATING RANGES
NV242 operating ranges are 2WD (2-wheel drive),
4x4 part-time, 4x4 full time, and 4 Lo.
The 2WD and 4x4 full time ranges can be used at
any time and on any road surface.
The 4x4 part-time and 4 Lo ranges are for off road
use only. The only time these ranges can be used on
hard surface roads, is when the surface is covered
with snow and ice.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted
shift lever. The shift lever is connected to the trans-
fer case range lever by an adjustable linkage rod. A
straight line shift pattern is used. Range positions
are marked on the shifter bezel cover plate, or on the
shift knob.
LUBRICANT AND FILL LEVEL
DESCRIPTION
Recommended lubricant for the NV242 transfer
case is Mopar
t Dexron II, or ATF Plus, type 7176.
Approximate lubricant fill capacity is 1.35 liters (2.85
pints).
The fill and drain plugs are both in the rear case
(Fig. 3). Correct fill level is to the bottom edge of the
fill plug hole. Be sure the vehicle is level to ensure
an accurate fluid level check.
DIAGNOSIS AND TESTING
NV242 DIAGNOSIS
DIAGNOSIS CHART
CONDITION
POSSIBLE CAUSE
CORRECTION
Transfer case difficult to shift or will
not shift into desired range.
1) Transfer case shift linkage
binding.
1) Repair or replace linkage as
necessary.
2) Insufficient or incorrect lubricant.
2) Drain and refill transfer case with
the correct type and quantity of
lubricant.
3) Internal transfer case
components binding, worn, or
damaged.
3) Repair or replace components as
necessary.
Transfer case noisy in all drive
modes.
1) Insufficient or incorrect lubricant.
1) Drain and refill transfer case with
the correct type and quantity of
lubricant.
Lubricant leaking from transfer case
seals or vent.
1) Transfer case overfilled.
1) Drain lubricant to the correct
level.
2) Transfer case vent closed or
restricted.
2) Clean or replace vent as
necessary.
3) Transfer case seals damaged or
installed incorrectly.
3) Replace suspect seal.
Fig. 3 Fill/Drain Plug Locations
1 – I. D. TAG
2 – FILL PLUG
3 – DRAIN PLUG
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NV242 TRANSFER CASE
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DESCRIPTION AND OPERATION (Continued)
CONDITION
POSSIBLE CAUSE
CORRECTION
Transfer case will not shift through
4X4 part time range (light remains
on)
1) Incomplete shift due to drivetrain
torque load.
1) Momentarily release the
accelerator pedal to complete the
shift.
2) Incorrect tire pressure.
2) Correct tire pressure as
necessary.
3) Excessive Tire wear.
3) Correct tire condition as
necessary.
4) Excessive vehicle loading.
4) Correct as necessary.
REMOVAL AND INSTALLATION
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) Support transmission with jack stand.
(6) Remove rear crossmember, or skid plate.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires.
(9) Disconnect transfer case linkage rod from
range lever.
(10) Disconnect transfer case vent hose (Fig. 4)
and indicator switch harness, if necessary.
(11) Support transfer case with transmission jack.
(12) Secure transfer case to jack with chains.
(13) Remove nuts attaching transfer case to trans-
mission.
(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N·m (26 ft. lbs.) torque (Fig. 4).
(6) Connect vehicle speed sensor wires, and vent
hose.
(7) Connect indicator switch harness to transfer
case switch, if necessary. Secure wire harness to clips
on transfer case.
(8) Align and connect propeller shafts. Refer to
Group 3, Differential and Driveline, for proper proce-
dures and specifications.
(9) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(10) Install
rear
crossmember,
or
skid
plate.
Tighten crossmember bolts to 41 N·m (30 ft. lbs.)
torque.
(11) Remove transmission jack and support stand.
(12) Connect shift rod to transfer case range lever.
(13) Adjust transfer case shift linkage.
(14) Lower vehicle and verify transfer case shift
operation.
SHIFT LEVER
REMOVAL
(1) Shift transfer case into 4L.
(2) Raise vehicle.
(3) Loosen adjusting trunnion locknut and slide
shift rod out of trunnion (Fig. 5). If rod lacks enough
travel to come out of trunnion, push trunnion out of
torque shaft.
(4) Lower vehicle.
(5) Remove console. Refer to Group 23, Body, for
proper procedures.
Fig. 4 Transfer Case Mounting
1 – VENT TUBE
2 – TRANSFER CASE
3 – TRANSMISSION
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NV242 TRANSFER CASE
21 - 377
DIAGNOSIS AND TESTING (Continued)
(6) Remove screws attaching lever assembly to
floorpan and remove assembly and shift rod (if left
attached).
INSTALLATION
(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
assembly attaching screws.
(2) Install console. Refer to Group 23, Body, for
proper procedures.
(3) Raise vehicle.
(4) Connect trunnion to torque shaft arm. Or, slide
shift rod into trunnion on range lever. Be sure shift
rod slides freely in trunnion.
(5) Verify that range lever is in 4L position. Then
tighten trunnion lock bolt.
(6) Lower vehicle and check transfer case shift
operation.
SPEEDOMETER
REMOVAL
(1) Raise vehicle.
(2) Disconnect wires from vehicle speed sensor.
(3) Remove adapter clamp and screw (Fig. 6).
(4) Remove speed sensor and speedometer adapter
as an assembly.
(5) Remove speed sensor retaining screw and
remove sensor from adapter.
(6) Remove
speedometer
pinion
from
adapter.
Replace pinion if chipped, cracked, or worn.
(7) Inspect sensor and adapter O-rings (Fig. 6).
Remove and discard O-rings if worn or damaged.
(8) Inspect terminal pins in speed sensor. Clean
pins with Mopar
t electrical spray cleaner if dirty or
oxidized. Replace sensor if faulty, or if pins are loose,
severely corroded, or damaged.
Fig. 5 Shift Linkage
1 – RIVNUT (4)
2 – SHIFT LEVER ASSEMBLY
3 – FLOORPAN
4 – TRUNNION LOCK BOLT
5 – SELECTOR ROD AND TRUNNION
6 – SHIFT LEVER ROD
7 – TORQUE SHAFT FRAME BRACKET
8 – TORQUE SHAFT
9 – TRANSFER CASE SHIFT LEVER
10 – TORQUE SHAFT TRANSFER CASE BRACKET
TORQUE
A
3-4 N
•
m (27-35 in. lbs.)
B
11-14 N
•
m (97-123 in. lbs.)
C
8-14 N
•
m (72-120 in. lbs.)
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NV242 TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
INSTALLATION AND INDEXING
(1) Thoroughly clean adapter flange and adapter
mounting surface in housing. Surfaces must be clean
for proper adapter alignment and speedometer oper-
ation.
(2) Install new O-rings on speed sensor and speed-
ometer adapter (Fig. 6), if necessary.
(3) Lubricate sensor and adapter O-rings with
transmission fluid.
(4) Install vehicle speed sensor in speedometer
adapter. Tighten sensor attaching screw to 2-3 N·m
(15-27 in. lbs.) torque.
(5) Install speedometer pinion in adapter.
(6) Count number of teeth on speedometer pinion.
Do this before installing assembly in housing. Then
lubricate pinion teeth with transmission fluid.
(7) Note index numbers on adapter body (Fig. 7).
These numbers will correspond to number of teeth on
pinion.
(8) Install speedometer assembly in housing.
(9) Rotate adapter until required range numbers
are at 6 o-clock position. Be sure range index num-
bers correspond to number of teeth on pinion gear.
(10) Install speedometer adapter clamp and retain-
ing screw. Tighten clamp screw to 10-12 N·m (90-110
in. lbs.) torque.
(11) Connect wires to vehicle speed sensor.
(12) Lower vehicle and top off transmission fluid
level if necessary.
FRONT OUTPUT SHAFT SEAL
REMOVAL
(1) Raise vehicle.
(2) Remove front propeller shaft. Refer to Group 3,
Differential and Driveline, for proper procedure.
Fig. 6 Speedometer Components
1 – SENSOR O-RING
2 – SPEEDOMETER ADAPTER
3 – ADAPTER O-RING
4 – SPEEDOMETER PINION
5 – ADAPTER CLAMP
6 – VEHICLE SPEED SENSOR
ITEM
TORQUE
A
2-3 N·m (15-27 in. lbs.)
B
10-12 N·m (90-110 in. lbs.)
Fig. 7 Location Of Index Numbers On Speedometer
Adapter
1 – SPEEDOMETER ADAPTER
2 – INDEX NUMBER LOCATION
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NV242 TRANSFER CASE
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REMOVAL AND INSTALLATION (Continued)
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