Jeep Wrangler TJ. Manual — part 529
(6) Remove bolt (Fig. 12) that retains the shift
lever to sector shaft.
(7) Remove the shift lever (Fig. 13) from the shift
sector.
(8) Remove the detent plug (Fig. 14).
Fig. 14 Detent Plug Removal
1 - DETENT PLUG
2 - SPRING
Fig. 11 Front Yoke Removal
1 - TRANSFER CASE
2 - FRONT YOKE
Fig. 12 Shift Lever Bolt Removal
1 - SHIFT LEVER
2 - BOLT
3 - SECTOR SUPPORT
Fig. 13 Shift Lever Removal
1 - SHIFT LEVER
2 - SECTOR SUPPORT
3 - SHIFT SECTOR
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TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
(9) Remove the detent plug (Fig. 15), spring, and
plunger from the transfer case.
(10) Remove the transfer case position sensor (Fig.
16).
(11) Remove the shift sector support (Fig. 17).
MAINSHAFT, FRONT OUTPUT SHAFT, AND DRIVE
CHAIN
(1) Note position of bolts that attach rear case to
front case. Some bolts are unique. Mark position of
these bolts with paint or scriber.
(2) Remove rear case-to-front case bolts (Fig. 18).
(3) Loosen rear case with pry tool to break sealer
bead.
Fig. 15 Detent Plug, Spring, and Plunger Removal
1 - DETENT PLUG
2 - SPRING
3 - PLUNGER
Fig. 16 Remove Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 17 Shift Sector Support Removal
1 - SHIFT SECTOR SHAFT
2 - SECTOR SUPPORT
Fig. 18 Case Half Bolt Removal
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - BOLTS
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TRANSFER CASE - NV241
21 - 207
TRANSFER CASE - NV241 (Continued)
(4) Unseat rear case from alignment dowels (Fig.
19).
(5) Remove rear case and oil pump assembly from
front case (Fig. 20).
CAUTION: Do not remove the bolts holding the oil
pump cover to the rear case half. The oil pump
cover is aligned to the rear output shaft bearing
inner race and will become mis-aligned if the bolts
are loosened. If the transfer case failure has gener-
ated any debris which may have become trapped in
the oil pump, the rear case and oil pump assembly
MUST be replaced.
(6) Remove shift rail cups and spring (Fig. 21).
(7) Remove front drive sprocket retaining ring
(Fig. 22).
Fig. 19 Case Alignment Dowel
1 - REAR CASE HALF
2 - FRONT CASE HALF
3 - ALIGNMENT DOWEL
Fig. 20 Rear Case Half Removal
1 - REAR CASE HALF
2 - FRONT CASE HALF
Fig. 21 Shift Rail Cup And Spring Removal
1 - SHIFT RAIL
2 - SPRING
3 - CUPS (2)
Fig. 22 Front Drive Sprocket Snap-Ring Removal
1 - DRIVE CHAIN
2 - FRONT DRIVE SPROCKET
3 - SNAP-RING
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TRANSFER CASE - NV241
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TRANSFER CASE - NV241 (Continued)
(8) Remove mainshaft, front sprocket, and chain as
an assembly (Fig. 23).
SHIFT FORKS
(1) Remove front output shaft from bearing in case
(Fig. 24).
(2) Remove the shift rail (Fig. 25) from the shift
forks.
(3) Remove mode fork, mode sleeve (Fig. 26). Note
which way sleeve fits in fork (long side of sleeve goes
to front).
Fig. 23 Remove Mainshaft, Drive Chain, and Front
Sprocket
1 - MAINSHAFT
2 - DRIVE CHAIN
3 - DRIVE SPROCKET
Fig. 24 Front Output Shaft Removal
1 - FRONT CASE HALF
2 - FRONT OUTPUT SHAFT
Fig. 25 Shift Fork Rail Removal
1 - FRONT CASE HALF
2 - SHIFT RAIL
Fig. 26 Mode Fork and Sleeve Removal
1 - MODE FORK
2 - MODE SLEEVE
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TRANSFER CASE - NV241
21 - 209
TRANSFER CASE - NV241 (Continued)
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