Jeep Liberty KJ. Manual — part 1235
SHIFT FORKS AND MAINSHAFT
1. Lubricate mainshaft splines with recommended
transmission fluid.
2. Install the mode hub (1) onto the output shaft.
3. Install the mode hub retaining ring (2) onto the out-
put shaft (1).
4. Install the sprocket hub (2) onto the output shaft
(1).
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5. Install the clutch gear (2) onto the output shaft (1).
6. Install the drive sprocket (2) onto the output shaft
(1).
7. Install the drive sprocket (3) thrust washer (2) onto
the output shaft (1).
KJ
TRANSFER CASE - NV241 GENII
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8. Install the drive sprocket retaining ring (2) onto the
output shaft (1).
9. Lubricate sector shaft with transmission fluid and
install shift sector (1) in case. Position slot in sector
so it will be aligned with shift fork pin when shift
forks are installed.
10. Install the shift sector support (1). Tighten the sec-
tor support to 27-42 N·m (20-30 ft.lbs.).
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11. Assemble and install range fork (2) and hub (1).
Be sure hub is properly seated in low range gear
and engaged to the input gear.
12. Align and insert range fork pin in shift sector slot.
13. Install the range fork retaining ring.
14. Install mode fork (1) and shift rail (2) onto the
mode sleeve (3).
15. Install the mode fork, sleeve, and shift rail into the
transfer case.
16. Install mainshaft (2) into the transfer case (1).
Guide mainshaft through the mode and range
sleeves and into the input gear.
KJ
TRANSFER CASE - NV241 GENII
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