Jeep Liberty KJ. Manual — part 1251
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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TRANSFER CASE - NV242
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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 - NV242
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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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SEAL-REAR OUTPUT SHAFT
REMOVAL
1. Shift the transmission and transfer case into NEU-
TRAL.
2. Raise and support vehicle.
3. Mark a line across the pinion shaft and at each end
of the propeller shaft for installation reference.
4. Remove the U-joint strap bolts at the pinion shaft
yoke.
5. Pry open clamp holding the dust boot (2) to propel-
ler shaft yoke.
6. Slide the slip yoke off of the transmission/transfer
case output shaft and remove the propeller shaft.
7. Spread band clamp which holds output shaft boot
to the output shaft slinger with a suitable awl, or
equivalent.
8. Remove output shaft boot from slinger and output
shaft.
9. Remove the output shaft rear slinger (3) using
Puller MD-998056-A (2).
10. Use a suitable pry tool, or a slide hammer
mounted screw, to remove the seal (2) from the
rear retainer (1).
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TRANSFER CASE - NV242
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