Jeep XJ. Manual — part 806
(3) Remove mode fork and sleeve as an assembly
(Fig. 16). Note position of sleeve for assembly refer-
ence. The short side of the sleeve faces upward.
(4) Remove range fork and hub as an assembly
(Fig. 17). Note fork position for installation reference.
(5) Remove shift sector from front case (Fig. 18).
(6) Remove shift sector bushing and O-ring (Fig.
19).
MAINSHAFT
(1) Remove mode hub retaining ring with heavy
duty snap-ring pliers (Fig. 20).
(2) Slide mode hub off mainshaft (Fig. 21).
(3) Slide drive sprocket off mainshaft (Fig. 22).
Fig. 16 Mode Fork And Sleeve Removal
1 - MODE SLEEVE
2 - MODE FORK AND RAIL
Fig. 17 Range Fork And Hub Removal
1 - RANGE HUB
2 - RANGE FORK
Fig. 18 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 19 Sector Bushing And O-Ring Removal
1 - SEAL RETAINER
2 - SECTOR SHAFT BORE
3 - O-RING SEAL
21s - 46
TRANSFER CASE NV-231
XJ
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
INPUT GEAR AND LOW RANGE GEAR
(1) Remove front bearing retainer attaching bolts
(Fig. 23).
(2) Remove front bearing retainer. Pry retainer
loose with pry tool positioned in slots at each end of
retainer (Fig. 24).
(3) Remove front bearing retainer seal. Tap seal
out with drift and hammer.
(4) Remove input gear retaining ring with heavy
duty snap-ring pliers (Fig. 25)
Fig. 20 Mode Hub Retaining Ring Removal
1 - MODE HUB
2 - SNAP-RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING
Fig. 21 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 22 Drive Sprocket Removal
1 - DRIVE SPROCKET
2 - MAINSHAFT
Fig. 23 Front Bearing Retainer Bolts
1 - FRONT CASE
2 - FRONT BEARING RETAINER
3 - RETAINER BOLTS
XJ
TRANSFER CASE NV-231
21s - 47
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
(5) Place front case in horizontal position. Then
remove input gear and low range gear as an assem-
bly (Fig. 26). Tap gear out of bearing with plastic
mallet if necessary.
INPUT AND LOW RANGE GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 27).
(2) Remove retainer (Fig. 28).
(3) Remove front tabbed thrust washer (Fig. 29).
(4) Remove input gear (Fig. 30).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 31).
Fig. 24 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
Fig. 25 Removing Input Gear Retaining Ring
1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
3 - SNAP-RING PLIERS
Fig. 26 Input Gear And Planetary Carrier Removal
1 - PLANETARY ASSEMBLY
2 - INPUT GEAR
Fig. 27 Input Gear Snap-Ring Removal
1 - CARRIER LOCK RETAINING RING
2 - INPUT GEAR
3 - PLANETARY CARRIER
4 - SCREWDRIVER
21s - 48
TRANSFER CASE NV-231
XJ
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
ASSEMBLY
Lubricate transfer case components with Mopar
t
ATF +4, type 9602, Automatic Transmission Fluid or
petroleum jelly (where indicated) during assembly.
BEARINGS AND SEALS
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 28 Input Gear Retainer Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 29 Front Tabbed Thrust Washer Removal
1 - FRONT TABBED THRUST WASHER
Fig. 30 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 31 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
XJ
TRANSFER CASE NV-231
21s - 49
TRANSFER CASE NV-231 (Continued)
2001 JEEP CHEROKEE
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