Jeep Liberty KJ. Manual — part 1233
3. Remove front tabbed thrust washer (1).
4. Remove input gear (1).
5. Remove rear tabbed thrust washer (2) from low
range gear (1).
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.
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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 input gear (6). Minor nicks can be dressed off with an oilstone but replace the gear if any
teeth are broken, cracked, or chipped. The bearing surface on the gear can be smoothed with 300-400 grit emery
cloth if necessary.
Examine the planetary carrier body (1) 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.
Check the carrier lock ring (4) and both thrust washers (2, 3) for wear or cracks. Replace them if necessary. Also
replace the carrier lock retaining ring (5) if bent, distorted, or broken.
Input Gear And Carrier Components
1 - PLANETARY CARRIER
4 - CARRIER LOCK RING
2 - REAR THRUST WASHER
5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER
6 - INPUT GEAR
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SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork shift
rail (2). Minor nicks on the shift rail can be smoothed
with 320-400 grit emery cloth.
Inspect the shift fork wear pads (3, 4). The mode fork
pads are serviceable and can be replaced if neces-
sary. The range fork pads are not serviceable. The
fork must be replaced as an assembly if the pads are
worn or damaged.
Check both of the sleeves for wear or damage, espe-
cially on the interior teeth. Replace the sleeves if wear
or damage is evident.
REAR RETAINER COMPONENTS
Inspect the retainer components. Replace the bearing if rough or noisy. Check the retainer for cracks or wear in the
bearing bore.
Inspect the retaining rings and washers. Replace any part if distorted, bent, or broken. Reuse is not recommended.
Inspect rear extension bushing. Replace if worn or scored.
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.
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LOW RANGE ANNULUS GEAR
Inspect annulus gear (2) condition carefully. The gear
is only serviced as part of the front case. If the gear is
damaged, it will be necessary to replace the gear and
front case as an assembly. Do not attempt to remove
the gear.
FRONT CASE AND REAR CASE
Inspect the cases for wear and damage.
Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also
make sure the front case mounting studs are in good condition.
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™ stainless steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disas-
semble the pump as individual parts are not available. The pump is only available as a complete assembly. The
pickup screen, hose, and tube are the only serviceable parts and are available separately.
ASSEMBLY
BEARINGS AND SEALS
1. Remove the input shaft bearing (1) from the front
case (2) with suitable snap-ring pliers.
2. Transfer the retaining ring to the new bearing if
necessary and install the bearing into the front
case.
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