Jeep Liberty KJ. Manual — part 1238
SEAL-EXTENSION HOUSING
REMOVAL
1. Raise and support vehicle.
2. Remove rear propeller shaft. (Refer to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
3. Using a suitable pry tool or slide-hammer mounted screw, remove the extension housing seal.
INSTALLATION
1. Clean fluid residue from sealing surface and
inspect for defects.
2. Using Seal Installer D-163 (2) and Universal Han-
dle C-4171 (1), install seal in extension housing.
3. Install propeller shaft. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
4. Verify proper transfer case fluid level.
5. Lower vehicle.
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FLUID
STANDARD PROCEDURE - FLUID DRAIN AND FILL
The fill (2) and drain (3) plugs are both in the rear
case. Correct fill level is to the bottom edge of the fill
plug hole. Be sure the vehicle is level to ensure an
accurate fluid level check.
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TRANSFER CASE - NV241 GENII
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SEAL-FRONT OUTPUT SHAFT
REMOVAL
1. Raise vehicle.
2. Remove front propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
3. Remove front output shaft companion flange.
4. Remove seal (1) from front case with pry tool (2).
INSTALLATION
1. Install new front output seal in front case (2) with
Installer Tool 6952-A (1) as follows:
a. Place new seal on tool. Garter spring on seal
goes toward interior of case.
b. Start seal in bore with light taps from hammer.
Once seal is started, continue tapping seal into
bore until installer tool seats against case.
2. Install the front output shaft companion flange.
Tighten the companion flange nut to 149 N·m (110
ft.lbs.).
3. Install the front propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION)
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SENSOR-POSITION
DESCRIPTION
The transfer case position sensor (2) is an electronic
device whose output can be interpreted to indicate the
transfer case’s current operating mode. The sensor
consists of a five position, resistive multiplexed circuit
which returns a specific resistance value to the Pow-
ertrain Control Module (PCM) for each transfer case
operating mode. The sensor is located on the top of
the transfer case, just left of the transfer case center-
line and rides against the sector plate roostercomb.
The PCM supplies 5VDC (+/- 0.5V) to the sensor and
monitors the return voltage to determine the sector
plate, and therefore the transfer case, position.
OPERATION
During normal vehicle operation, the Powertrain Con-
trol Module (PCM) monitors the transfer case position
sensor return voltage to determine the operating mode
of the transfer case. Refer to the Operating Mode Ver-
sus Resistance table for the correct resistance for
each position.
Operating Mode Versus Resistance
SENSOR POSITION
OPERATING MODE
SENSOR RESISTANCE (ohms)
1
2WD
1124-1243
2
4WD PART TIME
650-719
3
4WD FULL TIME
389-431
4
NEUTRAL
199-221
5
4WD LOW
57-64
Position Sensor Linear Movement
1 - POSITION 1 - 10mm ±0.5mm
2 - POSITION 2 - 12mm ±0.5mm
3 - POSITION 3 - 14mm ±0.5mm
4 - POSITION 4 - 16mm ±0.5mm
5 - POSITION 5 - 18mm ±0.5mm
6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION
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TRANSFER CASE - NV241 GENII
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