Jeep Liberty KJ. Manual — part 1249
4. Install drive sprocket (1) snap-ring (2).
OIL PUMP AND REAR CASE
1. Insert oil pickup tube (4) in oil pump (1) and attach
oil screen (2) and connector hose (3) to pickup
tube. Then install assembled pump, tube and
screen in rear case. Be sure screen is seated in
case slot as shown.
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2. Install magnet in front case pocket.
3. Apply 3 mm (1/8 in.) wide bead of Mopar
T
gasket
maker or silicone adhesive sealer to seal surface of
front case.
4. Align and install rear case on front case. Be sure
case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
5. Install and tighten front case-to-rear case bolts to
41 N·m (30 ft. lbs.) torque. Be sure to install a
washer under each bolt used at case dowel
locations.
REAR RETAINER
1. Remove rear bearing in retainer using Installer
8128 and Handle C-4171.
2. Install rear bearing in retainer with Tools C-4171 (1)
and 5064 (2).
3. Install rear bearing O.D. retaining ring (1) with
snap-ring pliers (2). Be sure retaining ring is fully
seated in retainer groove.
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4. Apply bead of Mopar
T
Sealer P/N 82300234, or
Loctite™ Ultra Gray, to mating surface of rear
retainer. Sealer bead should be a maximum of 3/16
in.
5. Install rear retainer on rear case. Tighten retainer
bolts to 20-27 N·m (15-20 ft. lbs.) torque.
6. Install rear bearing I.D. retaining ring and spacer
on output shaft.
7. Apply liberal quantity of petroleum jelly to new rear
seal and to output shaft. Petroleum jelly is needed
to protect seal lips during installation.
8. Slide seal onto Seal Protector 8824 (2). Slide seal
protector and seal (1) onto output shaft.
9. Slide Installer 8691 (1) onto seal protector with the
recessed side of the tool toward the seal. Drive
seal into rear bearing retainer with Installer 8691.
10. Install rear slinger with Installer 9023.
11. Install boot (3) on output shaft slinger (2) and
crimp retaining clamp (4) with tool C-4975-A (1).
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COMPANION FLANGE AND RANGE LEVER
1. Install range lever (1) and bolt (2) on sector shaft.
Tighten bolt to 27-34 N·m (20-25 ft. lbs.) torque.
2. Inspect the o-ring on the transfer case position
sensor. Replace the o-ring if necessary.
3. Install the transfer case position sensor (1) in the
front case (2). Tighten sensor to 20-34 N·m (15-25
ft. lbs.) torque.
4. Install new seal washer (1) on front output shaft.
5. Lubricate companion flange hub with transmission
fluid and install flange onto the front ouput shaft.
6. Install new seal washer on front shaft.
7. Install new flange nut onto front output shaft.
8. Tighten flange nut to 122-176 N·m (90-130 ft. lbs.)
torque.
INSTALLATION
1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case on transmission.
5. Install and tighten transfer case attaching nuts to 35 N·m (26 ft. lbs.) torque.
6. Connect vent hose.
7. Connect transfer case position sensor connector to sensor.
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