Jeep Wrangler TJ. Manual — part 530
(4) Remove range fork and hub as an assembly
(Fig. 27). Note fork position for installation reference.
(5) Remove shift sector (Fig. 28).
MAINSHAFT
(1) Remove the snap-ring that secures the chain
drive sprocket onto mainshaft (Fig. 29). Use standard
(instead of parallel jaw) snap-ring pliers to remove
this snap-ring.
(2) Remove drive sprocket (Fig. 30).
Fig. 27 Range Fork and Hub Removal
1 - RANGE FORK
2 - RANGE HUB
Fig. 28 Shift Sector Removal
1 - FRONT CASE HALF
2 - SHIFT SECTOR
Fig. 29 Mainshaft Drive Sprocket Snap-Ring
Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET
3 - SNAP-RING
Fig. 30 Mainshaft Drive Sprocket Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET
21 - 210
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
(3) Remove the sliding clutch gear (Fig. 31) from
the mainshaft.
(4) Rotate the mainshaft 180° and remove the
mode hub snap-ring (Fig. 32).
(5) Remove the mode hub (Fig. 33) from the main-
shaft.
(6) Remove the drive sprocket drive hub (Fig. 34)
from the mainshaft.
Fig. 31 Sliding Clutch Gear Removal
1 - MAINSHAFT
2 - SLIDING CLUTCH GEAR
Fig. 32 Mode Hub Snap-Ring Removal
1 - MAINSHAFT
2 - MODE HUB
3 - SNAP-RING
Fig. 33 Mode Hub Removal
1 - MAINSHAFT
2 - MODE HUB
Fig. 34 Drive Sprocket Drive Hub Removal
1 - MAINSHAFT
2 - DRIVE SPROCKET DRIVE HUB
TJ
TRANSFER CASE - NV241
21 - 211
TRANSFER CASE - NV241 (Continued)
INPUT AND PLANETARY GEAR
(1) Remove front input retainer attaching bolts
(Fig. 35).
(2) Remove the input gear seal with a suitable
screw and slide hammer.
(3) Remove the input gear snap-ring (Fig. 36) from
the input retainer.
(4) Remove the input gear (Fig. 37) from the input
gear bearing with suitable hammer.
(5) Remove front input retainer (Fig. 38).
Fig. 35 Front Input Retainer Bolt Removal
1 - INPUT RETAINER
2 - INPUT GEAR
3 - BOLT
4 - FRONT CASE HALF
Fig. 36 Input Gear Snap-Ring Removal
1 - INPUT RETAINER
2 - INPUT GEAR
3 - SNAP-RING
Fig. 37 Input Gear Removal
1 - INPUT RETAINER
2 - INPUT GEAR
Fig. 38 Front Input Retainer Removal
1 - INPUT RETAINER
2 - FRONT CASE HALF
21 - 212
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
(6) Remove the low range planetary plastic spacer
(Fig. 39) from the planetary carrier or back side of
the input retainer.
(7) Remove the low range planetary gear set (Fig.
40) from the front case half.
(8) Remove the annulus gear (Fig. 41) from the
front case half.
(9) Support the input retainer on Cup 8148 as
shown (Fig. 42).
(10) While
using
suitable
snap-ring
pliers
to
spread the input gear bearing snap-ring (Fig. 43),
press downward on the retainer to remove the bear-
ing.
Fig. 41 Remove Annulus Gear
1 - FRONT CASE HALF
2 - ANNULUS GEAR
Fig. 42 Support Input Gear Bearing For Removal
1 - INPUT RETAINER
2 - CUP 8148
3 - INPUT GEAR BEARING
Fig. 43 Input Gear Bearing Removal
1 - INPUT RETAINER
2 - CUP 8148
3 - INPUT GEAR BEARING
Fig. 39 Low Range Planetary Plastic Spacer
1 - LOW RANGE PLANETARY
2 - PLASTIC SPACER
Fig. 40 Low Range Planetary Removal
1 - FRONT CASE HALF
2 - LOW RANGE PLANETARY
3 - ANNULUS GEAR
TJ
TRANSFER CASE - NV241
21 - 213
TRANSFER CASE - NV241 (Continued)
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