1994 JEEP CHEROKEE Transfer case

NP242 SERVICE DIAGNOSIS
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SHIFT LINKAGE ADJUSTMENT
(1) Remove shift lever bezel.
(2) Move shift lever into 4L position.
(3) Insert 3 mm (1/8 in.) spacer between shift lever
and forward edge of shift lever gate (Fig. 4). Secure
lever and spacer in place with tape or wire.
(4) Raise vehicle.
(5) Loosen trunnion lock bolt (Fig. 5). Linkage rod
should now slide freely in trunnion.
(6) Verify that transfer case range lever is in 4L posi-
tion.
(7) Position linkage rod so it is free fit in range le-
ver (Fig. 5). Then tighten trunnion lock bolt.
(8) Lower vehicle.
(9) Remove shift lever spacer and install bezel.
SPEEDOMETER SERVICE
Speedometer service is covered in the automatic
transmission sections within this group.
TRANSFER CASE REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Place support stand under transmission.
(6) Remove rear crossmember.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires and re-
move sensor and adapter assembly if necessary.
(9) Disconnect transfer case shift rod from range lever.
(10) Disconnect transfer case vent hoses and elec-
trical switch connector.
(11) Support transfer case with transmission jack.
(12) Remove bolts attaching the transfer case to
transmission.
(13) Secure transfer case to jack with chains.(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
TRANSFER CASE INSTALLATION
(1) Mount transfer case on transmission jack. Se-
cure transfer case to jack with safety chains.
(2) Position transfer case under vehicle.
(3) Align transfer case and transmission shafts and
install transfer case on transmission.
(4) Install and tighten transfer case attaching nuts
to 35 Nzm (26 ft. lbs.) torque.
(5) Install vehicle speed sensor and adapter, if re-
moved. Then connect vehicle speed sensor wires, vent
hoses and electrical switch connector.
(6) Align and connect propeller shafts. Tighten shaft
U-joint clamp bolts to 19 Nzm (14 ft. lbs.) torque.
(7) Fill transfer case with recommended automatic
transmission fluid.
(8) Install rear crossmember. Tighten crossmember
bolts to 41 Nzm (30 ft. lbs.) torque.
(9) Remove transmission jack and transmission
support stand.
(10) Connect transfer case range lever to shift rod.
(11) Check and adjust transfer case shift linkage if
necessary.
(12) Lower vehicle.
Fig. 4 Installing Shift Lever Spacer
Fig. 5 Transfer Case Shift Linkage
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TRANSFER CASE DISASSEMBLY AND OVERHAUL
(1) Remove fill and drain plugs.
(2) Remove front yoke. Discard yoke seal washer
and nut.
(3) Move range lever rearward to 4L position.
(4) Remove extension housing attaching bolts.
(5) Tap extension housing in a clockwise direction
to break sealer bead and remove housing (Fig. 6).
CAUTION: To avoid damaging the sealing surfaces of
the extension housing and rear retainer, do not at-
tempt to pry or wedge the housing off the retainer.
(6) Remove rear bearing snap ring from mainshaft
(Fig. 7). Discard snap ring.(7) Remove rear retainer attaching bolts.
(8) Loosen rear retainer (Fig. 8). Position long
screwdriver under each tab at ends of retainer hous-
ing and pry retainer upward.
CAUTION: Do not pry against the sealing surfaces
of the retainer or rear case. The surfaces could be
damaged.
(9) Lift rear retainer up and off case and main-
shaft (Fig. 9).
Fig. 7 Removing Rear Bearing Snap Ring
Fig. 6 Extension Housing Removal
Fig. 8 Loosening Rear Retainer
Fig. 9 Remove Rear retainer
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(10) Remove bolts attaching rear case to front case.
Retain bolts and the washers.
(11) Loosen rear case with two screwdrivers (Fig.
10). Insert screwdrivers into slots cast in case ends.
Then gently pry upward to break sealer bead.
CAUTION: Do not pry against the sealing surfaces
of the front case or rear case. The surfaces could
be damaged.
(12) Remove rear case and oil pump as assembly
(Fig. 11).(13) Slide oil screen (Fig. 12) out of case pocket.
(14) Remove oil pump, pickup tube and oil screen
from rear case (Fig. 13).
(15) Remove pickup tube and screen from pump.
(16) Remove pickup tube O-ring from oil pump
(Fig. 14).
(17) Remove and discard oil pump seal.
(18) The oil pump can be disassembled for cleaning
and inspection as described in step (19).However,
pump parts are not serviceable separately. If
any pump component is worn, or damaged,
pump must be replaced as an assembly.
(19) If oil pump will be disassembled for inspec-
tion, mark position of oil pump housings for refer-
Fig. 10 Loosening Rear Case
Fig. 11 Removing Rear Case And Oil Pump
Fig. 12 Unseating Oil Screen
Fig. 13 Removing Oil Pump, Tube And Screen
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ence (Fig. 15). Remove screws that attach two halves
of the pump. Remove feed housing from gear housing
(Fig. 15). Then mark position of pump gears and re-
move them from housing (Fig. 15).(20) Remove magnet from front case.
(21) Remove drive sprocket snap ring (Fig. 16).
(22) Remove drive sprocket and chain (Fig. 17).
Fig. 14 Removing Pickup Tube O-Ring
Fig. 15 Oil Pump Components
Fig. 16 Removing Drive Sprocket Snap Ring
fig. 17 Removing Drive Sprocket And Chain
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(23) Remove front output shaft (Fig. 18).
(24) Remove transfer case shift lever nut and lever.
(25) Remove shift detent plug, spring and pin (Fig.
19).(26) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole (Fig. 20).
(27) Remove range fork lockpin with size number
one easy-out tool. Grip easy-out tool with locking pli-
ers and remove pin with counterclockwise, twist and
pull motion (Fig. 20).
(28) Remove shift rail by pulling it straight up and
out of fork (Fig. 21).
Fig. 18 Removing Front Output Shaft
Fig. 19 Removing Detent Components
Fig. 20 Removing Low Range Fork Lockpin
Fig. 21 Removing Shift Rail
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(29) Remove mode fork and mainshaft as assembly
(Fig. 22).
(30) Remove mode shift sleeve and mode fork as-
sembly from mainshaft (Fig. 23). Note position of
mode sleeve in fork and remove sleeve.(31) Remove intermediate clutch shaft snap ring
(Fig. 24).
(32) Remove clutch shaft thrust ring (Fig. 25).
Fig. 22 Removing Mode Fork And Mainshaft
Fig. 23 Removing Mode Fork And Sleeve
Fig. 24 Removing Intermediate Clutch Shaft Snap
Ring
Fig. 25 Removing Clutch Shaft Thrust Ring
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(33) Remove intermediate clutch shaft (Fig. 26).
(34) Remove differential snap ring (Fig. 27).(35) Remove differential (Fig. 28).
(36) Remove differential needle bearings and both
needle bearing thrust washers from mainshaft.
(37) Slide low range fork pin out of shift sector slot
(Fig. 29)
Fig. 26 Removing Intermediate Clutch Shaft
Fig. 27 Removing Differential Snap Ring
Fig. 28 Differential Removal
Fig. 29 Disengage Low Range Fork
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