Jeep Liberty KJ. Manual — part 1248

14. Install clutch shaft (2) snap-ring (1).

15. Inspect mode fork assembly. Replace pads (5)

and bushing (3), if necessary. Replace fork tube
(4) if bushings inside tube are worn or damaged.
Also check springs (3) and slider bracket. Replace
worn, damaged components.

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KJ

16. Install mode sleeve (2) in mode fork (3). Then

install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in dif-
ferential splines.

17. Install mode fork (2) and mainshaft assembly (1)

in case. Rotate mainshaft slightly to engage shaft
with low range gears.

18. Rotate mode fork pin into shift sector slot.

KJ

TRANSFER CASE - NV242

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19. Install shift rail (1). Be sure rail is seated in both

shift forks.

20. Rotate shift sector to align lockpin hole in low

range fork with access hole in case.

21. Insert an easy-out (3) in range fork lockpin (1) to

hold it securely for installation. Lockpin is slightly
tapered on one end. Insert tapered end into fork
and rail.

22. Insert lockpin through access hole and into shift

fork. Then remove easy-out and seat the pin with
pin punch.

23. Install plug in lockpin access hole.

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24. Install detent plunger (1), detent spring (4), and

detent plug (3) in case.

FRONT OUTPUT SHAFT AND DRIVE CHAIN

1. Install front output shaft.

2. Install drive chain (2). Engage chain with front out-

put shaft sprocket teeth.

3. Install drive sprocket (1). Engage drive sprocket

teeth with chain. Then engage sprocket splines
with mainshaft splines.

KJ

TRANSFER CASE - NV242

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