Jeep Wrangler TJ. Manual — part 531
(11) Remove the front output shaft bearing with
Handle C-4171 and Installer 8239 (Fig. 44).
(12) Remove the rear output shaft bearing with
Handle C-4171 and Installer 8239 (Fig. 45).
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3M™ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.
INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone, however, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear. Minor nicks can be
dressed off with an oilstone but replace the gear if
any teeth are broken, cracked, or chipped. The bear-
ing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged. Inspect the plastic washer on the
inside, bottom of the planetary carrier. The washer is
trapped by the pinion gears and the complete plane-
tary will need to be replaced if the washer is worn or
damaged.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail. Minor nicks on the shift rail can be
smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads. The mode and
range fork pads are serviceable and can be replaced
if necessary.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
DRIVE CHAIN
Examine the drive chain and shaft bearings.
replace the chain if stretched, distorted, or if any of
the links bind. Replace the bearings if rough, or
noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
can be serviced separately.
FRONT-REAR CASES
Inspect the cases for wear and damage. Replace
the input retainer seal, do not reuse it.
Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Fig. 44 Front Output Bearing Removal
1 - HANDLE C-4171
2 - INSTALLER 8239
Fig. 45 Rear Output Bearing Removal
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 8239
21 - 214
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
Check the front case mounting studs and vent
tube. The tube can be secured with Loctite™ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with Helicoil™ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any evidence of debris or damage exists. Do
not disassemble the pump from the rear case half as
individual parts are not available and it will not be
possible to reassemble the pump cover to the rear
case half. The pump is only available as part of the
rear case half assembly. The pickup screen, hose, and
tube are the only serviceable parts and are available
separately.
ASSEMBLY
BEARINGS AND SEALS
(1) Position the input gear bearing in the input
retainer bearing bore. Spread the snap-ring captured
in the retainer with suitable snap-ring pliers and
press the bearing into place. Verify that the snap-
ring has engaged the groove in the bearing.
(2) Start front output shaft bearing in case (Fig.
46). Then seat bearing with Handle C-4171 and
Installer 6953.
(3) Install the front output shaft bearing retaining
ring.
(4) Install the rear output shaft bearing into the
rear case half with Installer 6953 and Handle C-4171
(Fig. 47).
(5) Remove the input gear pilot bearing using
Puller Jaws 8240 and Cup 8148.
(6) Remove the input gear cup plug (Fig. 48) with
a suitable drift and hammer inserted from the front
of the input gear.
(7) Install
a
new
input
gear
cup
plug
with
Installer 9045 and Handle C-4171.
Fig. 46 Front Output Shaft Bearing Installation
1 - HANDLE C-4171
2 - INSTALLER 6953
3 - BEARING
Fig. 47 Rear Output Bearing Installation
1 - REAR CASE HALF
2 - HANDLE C-4171
3 - INSTALLER 6953
Fig. 48 Remove Input Gear Cup Plug
1 - DRIFT
2 - INPUT GEAR
TJ
TRANSFER CASE - NV241
21 - 215
TRANSFER CASE - NV241 (Continued)
(8) Install new input gear pilot bearing with
Installer 9047 and Handle C-4171.
(9) Remove the front output shaft rear bearing
with the screw and jaws from Remover L-4454 and
Cup 8148 (Fig. 49).
(10) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 50). The bearing bore is
chamfered at the top. Install the bearing so it is
flush with the lower edge of this chamfer (Fig. 51).
Fig. 49 Front Output Shaft Rear Bearing Removal
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 50 Output Shaft Rear Bearing Installation
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 51 Output Shaft Rear Bearing Installation Depth
1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER
21 - 216
TRANSFER CASE - NV241
TJ
TRANSFER CASE - NV241 (Continued)
INPUT AND PLANETARY GEAR
(1) Install the annulus gear (Fig. 52) into the front
case half.
(2) Align and install low range planetary assembly
into the front case half (Fig. 53). Be sure low range
planetary pinions are engaged in annulus gear.
(3) Install the low range planetary plastic spacer
(Fig. 54) onto the low range planetary carrier.
(4) Clean gasket sealer residue from retainer and
inspect retainer for cracks or other damage.
(5) Apply a 3 mm (1/8 in.) bead of Mopar
t Gasket
Maker, or equivalent silicone adhesive, to sealing
surface of retainer.
(6) Install the front input retainer (Fig. 55) onto
the front case half.
(7) Install bolts to hold retainer to transfer case
(Fig. 56). Tighten to 21 N·m (16 ft. lbs.) of torque.
Fig. 52 Install Annulus Gear
1 - FRONT CASE HALF
2 - ANNULUS GEAR
Fig. 53 Low Range Planetary Installation
1 - FRONT CASE HALF
2 - LOW RANGE PLANETARY
3 - ANNULUS GEAR
Fig. 54 Low Range Planetary Plastic Spacer
1 - LOW RANGE PLANETARY
2 - PLASTIC SPACER
Fig. 55 Front Input Retainer Installation
1 - INPUT RETAINER
2 - FRONT CASE HALF
TJ
TRANSFER CASE - NV241
21 - 217
TRANSFER CASE - NV241 (Continued)
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