Jeep Liberty KJ. Manual — part 1220
11. Remove pick-up tube o-ring (2) from oil pump (1),
if necessary. Do not disassemble the oil pump, it
is not serviceable.
COMPANION FLANGE AND RANGE LEVER
1. Remove transfer case position sensor (1).
2. Install two bolts (2) partially into the propeller 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.
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4. Use Remover C-452 (3) to remove the companion
flange (2).
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.
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.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Support transfer case so rear case is facing
upward.
2. Remove bolts (2) holding front case to rear case.
The case alignment bolts require flat washers (1).
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3. Loosen rear case (1) with flat blade screwdriver to
break sealer bead. Insert pry tool (2) blade only
into notches provided at each end of case.
4. Remove rear case from front case.
5. Remove oil pickup tube (2) from rear case.
6. Remove mode fork spring (1).
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7. Pull front output shaft (2) upward and out of front
output shaft bearing (3).
8. Remove front output shaft and chain.
SHIFT FORKS AND MAINSHAFT
1. Remove mainshaft from mode sleeve and input
gear pilot bearing.
2. Remove detent plug (3), O-ring (2), detent spring
(4), and detent plunger (1).
3. Remove mode fork (2) and sleeve (1) as an
assembly. Note position of sleeve for assembly ref-
erence. The short side of the sleeve faces upward.
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