Jeep Grand Cherokee WK. Manual — part 1560
56. Install the sector roller (1) onto the shift rail (2).
57. Using a suitable punch, align the holes in the sec-
tor roller with the hole in the shift rail and install
the roll-pin to secure the sector roller to the shft
rail.
58. Apply bead of Mopar
T
Gasket Maker, or equiva-
lent, to mating surface of rear housing as shown
(2). Keep sealer bead width to maximum of 3 mm
(1/8 inch). Do not use excessive amount of sealer
as excess could be displaced into the oil pump.
59. Install a new rear output shaft seal into the rear
cover with Installer C-3972A.
60. Install the rear cover (1) onto the rear housing (2).
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WK
61. Install the bolts (3) holding the rear cover (2) onto
the rear housing (1). Tighten the bolts to 25-28
N·m (18.5-20.5 ft.lbs.).
62. Install the shift motor and mode sensor assembly
(1) onto the shift sector (2) and the transfer case
(3).
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63. Install the bolts (1) to hold the shift motor and
mode sensor assembly (2) to the transfer case.
Tighten the bolts to 25-28 N·m (18.5-20.5 ft.lbs.).
64. Install the rear output shaft flange (1) onto the
output shaft (2).
65. Using Holder C-3281 (1), install the rear compan-
ion flange (2) nut. Tighten the bolts to 122-176
N·m (90-130 ft.lbs.).
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INSTALLATION
1. Mount transfer case (1) on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case (2) and transmission (3) shafts
and install transfer case onto transmission.
5. Install and tighten transfer case attaching nuts (2)
to 35 N·m (26 ft. lbs.) torque.
6. Connect the transfer case vent hose (4) to the
transfer case.
7. Install
rear
crossmember
and
skid
plate,
if
equipped.
8. Remove transmission jack and support stand.
9. Connect front propeller shaft and install rear pro-
peller shaft. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT
- INSTALLATION)
10. Fill transfer case with correct fluid. Check trans-
mission fluid level. Correct as necessary.
11. Install the transfer case fill plug (1). Tighten the
plug to 20-34 N·m (15-25 ft.lbs.).
12. Connect the shift motor and mode sensor wiring
connector.
13. Lower vehicle and verify transfer case shift
operation.
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