Jeep Liberty KJ. Manual — part 1231
OIL PUMP AND REAR CASE
1. Remove rear case(1)-to-front case (2) bolts (3).
2. Loosen rear case (1) with pry tool to break sealer
bead. Insert tool in slot (3) at each end of case.
3. Unseat rear case (1) from alignment dowels.
4. Remove rear case and oil pump assembly from
front case.
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 gen-
erated
any
debris
which
may
have
become
trapped in the oil pump, the rear case and oil
pump assembly MUST be replaced.
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TRANSFER CASE - NV241 GENII
KJ
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Remove shift rail (1) cup (3) and spring (2).
2. Remove front sprocket (1) retaining ring (2).
3. Pull mainshaft (3), front sprocket (1) and chain out-
ward about 25.4 mm (1-inch) simultaneously.
4. Remove chain from mainshaft drive sprocket and
remove front sprocket and chain as assembly.
KJ
TRANSFER CASE - NV241 GENII
21 - 869
SHIFT FORKS AND MAINSHAFT
1. Loosen detent plug (2).
2. Remove detent plug (2), spring (3), and plunger
(4). Note that the plug has an O-ring seal. Remove
and discard this seal.
3. Remove front output shaft (2) from bearing in the
front case (1).
4. Pull mainshaft assembly (2) out of input gear,
mode sleeve, and front case (1).
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TRANSFER CASE - NV241 GENII
KJ
5. Remove mode fork (1), mode sleeve (3), and shift
rail (2) as assembly. Note which way the sleeve fits
in the fork (long side of sleeve goes to front).
6. Remove range fork retaining ring.
7. Remove range fork (2) and hub (1) as an assem-
bly. Note fork position for installation reference.
8. Remove the shift sector support (1).
KJ
TRANSFER CASE - NV241 GENII
21 - 871
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