Jeep Liberty KJ. Manual — part 1230
Condition
Possible Cause
Correction
Lubricant leaking from output shaft
seal or vent.
1) Transfer case overfilled.
1) Drain lubricant to the correct
level.
2) Vent closed or restricted.
2) Clear or replace vent as
necessary.
3) Output shaft seals damaged or
installed incorrectly.
3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
Abnormal tire wear.
1) Extended operation on hard, dry
surfaces in the 4H position.
1) Operate vehicle in the 2H
position on hard, dry surfaces.
REMOVAL
1. Shift transfer case into NEUTRAL.
2. Raise vehicle.
3. Remove skid plate (1).
4. Drain transfer case lubricant.
5. Mark front and rear propeller shaft yokes for align-
ment reference.
6. Remove the front/rear propeller shafts at transfer
case. (Refer to 3 - DIFFERENTIAL & DRIVELINE/
PROPELLER
SHAFT/PROPELLER
SHAFT
-
REMOVAL)
7. Disconnect transfer case position sensor connector
(1) from the position sensor (2).
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TRANSFER CASE - NV241 GENII
KJ
8. Disconnect transfer case shift cable (2) at the
range lever.
9. Disconnect the transfer case shift cable (2) from
the shift cable bracket (5).
10. Disconnect transfer case vent hose (3).
11. Support transfer case (2) with transmission jack.
12. Secure transfer case to jack with chains.
13. Remove nuts attaching transfer case to transmis-
sion (1).
14. Pull transfer case and jack rearward to disengage
transfer case.
15. Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan. Remove drain plug and drain any remaining lubricant remaining in
case.
COMPANION FLANGE AND RANGE LEVER
1. Remove transfer case position sensor (1).
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TRANSFER CASE - NV241 GENII
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2. Install two bolts (2) partially into the propellor shaft
companion flange (3), 180° from each other.
3. Install the rectangular end of the Flange Holder
C-3281 (1) over the bolts to hold the companion
flange stationary and remove the nut holding the
companion flange to the output shaft.
4. Use Remover C-452 (3) to remove the companion
flange (2).
5. Remove seal washer from front output shaft. Dis-
card washer as it should not be reused.
6. Remove the bolt (2) that attaches the range lever
(1) to sector shaft. Then move sector to neutral
position and remove range lever from shaft.
NOTE: Be sure to note the orientation of the range
lever (lever up or down) so that it may be re-in-
stalled in the same direction.
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TRANSFER CASE - NV241 GENII
KJ
REAR EXTENSION
1. Remove rear extension (1) bolts.
2. Remove rear extension housing (1). Tap extension
once or twice with a plastic mallet to break sealer
bead and loosen it.
3. Remove output bearing (2) retaining ring (3) with
heavy duty snap-ring pliers.
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TRANSFER CASE - NV241 GENII
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