Jeep Liberty KJ. Manual — part 1239
REMOVAL
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor con-
nector from the position sensor (2).
3. Remove the position sensor from the transfer case.
INSTALLATION
1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 N·m (20 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.
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TRANSFER CASE - NV241 GENII
KJ
LEVER-SHIFT
REMOVAL
1. Shift transfer case into 4L.
2. Raise vehicle.
3. Remove clip securing the transfer case shift cable
(2) to the shift cable support bracket.
4. Disengage any additional shift cable routing clips, if
necessary.
5. Disengage the shift cable from the transfer case
manual lever.
6. Lower vehicle.
7. Remove the floor console as necessary to access
the shifter mechanism. (Refer to 23 - BODY/INTE-
RIOR/FLOOR CONSOLE - REMOVAL)
8. Remove the nuts attaching lever assembly (1) to
floorpan and remove assembly and shift cable (2).
9. Remove the shifter mechanism and cable assem-
bly from the vehicle.
INSTALLATION
1. Route the shift cable through the opening in the floor pan.
2. Position the shift mechanism over the shifter retaining studs on the floor pan.
3. Install the nuts to hold the shifter mechanism to the floor pan. Tighten the nuts to 11.86 N·m (105 in.lbs.).
4. Install any floor console components previously removed. (Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
INSTALLATION)
5. Verify that the floor shifter is in the 4L position.
6. Raise vehicle.
7. Route the shift cable through the opening in the shift cable support bracket.
8. Install the cable and a new spring clip into the slot in the support bracket.
9. Install any additional routing clips on the shift cable.
10. Verify that the transfer case is in the 4L position. The 4L position for the transfer case is with the manual lever
to the full rearward position.
11. Attach the shift cable to the transfer case manual lever.
12. Lower vehicle and check for proper transfer case shifter operation.
KJ
TRANSFER CASE - NV241 GENII
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TRANSFER CASE - NV242
TABLE OF CONTENTS
page
page
TRANSFER CASE - NV242
CASE - NV242 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 903
NV242 TRANSFER CASE . . . . . . . . . . . . . . . . . . . 944
TRANSFER CASE - NV242 . . . . . . . . . . . . . . . . . 945
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND
FILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947
SEAL-FRONT OUTPUT SHAFT
SENSOR-POSITION
SEAL-REAR OUTPUT SHAFT
LEVER-SHIFT
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TRANSFER CASE - NV242
KJ
TRANSFER CASE - NV242
DESCRIPTION
The NV242 is a full-time transfer case. It provides full time 2-wheel, or 4-wheel drive operation.
A differential in the transfer case is used to control torque transfer to the front and rear axles. A low range gear
provides increased low speed torque capability for off road operation. The low range provides a 2.72:1 reduction
ratio.
The geartrain is mounted in two aluminum case halves attached with bolts. The mainshaft front and rear bearings
are mounted in aluminum retainer housings bolted to the case halves.
TRANSFER CASE IDENTIFICATION
A circular ID tag (1) is attached to the rear case of
each transfer case. The ID tag provides the transfer
case model number, assembly number, serial number,
and low range ratio.
The transfer case serial number also represents the
date of build.
OPERATING RANGES
NV242 operating ranges are 2WD (2-wheel drive), 4x4 part-time, 4x4 full time, 4 Lo, and Neutral.
The 2WD and 4x4 full time ranges can be used at any time and on any road surface.
The 4x4 part-time and 4 Lo ranges are for off road use only. The only time these ranges can be used on hard
surface roads, is when the surface is covered with snow and ice.
SHIFT MECHANISM
Operating ranges are selected with a floor mounted shift lever. The shift lever is connected to the transfer case
range lever by a shift cable. A straight line shift pattern is used. Range positions are marked on the shifter bezel
cover plate, or on the shift knob.
OPERATION
The input gear is splined to the transmission output shaft. It drives the mainshaft through the planetary gear and
range hub. The front output shaft is operated by a drive chain that connects the shaft to a drive sprocket on the
mainshaft. The drive sprocket is engaged/disengaged by the mode fork, which operates the mode sleeve and hub.
The sleeve and hub are not equipped with a synchro mechanism for shifting.
DIAGNOSIS AND TESTING - TRANSFER CASE - NV242
DIAGNOSIS CHART
KJ
TRANSFER CASE - NV242
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