1994 JEEP CHEROKEE Service Repair Manual

(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
JNP242 TRANSFER CASE 21 - 301

(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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(38) Remove low range fork and hub (Fig. 30).
(39) Remove the shift sector (Fig. 31).(40) Remove shift sector bushing and O-ring (Fig.
32).
(41) Remove front bearing retainer bolts.
(42) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 33). Position the
screwdriver in the slots cast into retainer.
Fig. 30 Removing Low Range Fork And Hub
Fig. 31 Shift Sector Position
Fig. 32 Removing Sector Bushing And O-Ring
Fig. 33 Removing Front Bearing Retainer
JNP242 TRANSFER CASE 21 - 303

(43) Remove the input gear snap ring (Fig. 34).
(44) Press input and low range gears out of input
gear bearing and case (Fig. 35).(45) Remove the low range gear snap ring (Fig.
36).
(46) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 37).
Fig. 34 Removing Input Gear Snap Ring
Fig. 35 Removing Input And Low Range Gears
Fig. 36 Removing/Installing Low Range Gear Snap
Ring
Fig. 37 Low Range Gear Disassembly
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(47) Inspect the low range annulus gear (Fig. 38).
The gear is not a serviceable component. If
damaged, replace the gear and front case as an
assembly.
(48) Remove the oil seals from the rear retainer,
extension housing, oil pump and case halves.
(49) Mark differential case halves for reference.
(50) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 39).
(51) Remove thrust washers and planet gears from
case pins (Fig. 40).(52) Remove mainshaft and sprocket gears from
bottom case (Fig. 41). Note gear position for reference
before separating them.
CLEANING AND INSPECTION
Clean the transfer case components thoroughly
with solvent. Remove all traces of sealer from the
case and retainer seal surfaces.
Clean the oil pickup screen with solvent and dry it
with compressed air. Also use compressed air to re-
move solvent residue from all oil feed passages and
channels.
Fig. 38 Inspecting Low Range Annulus Gear
Fig. 39 Separating Differential Case Halves
Fig. 40 Removing Planet Gears And Thrust Washers
Fig. 41 Removing Mainshaft And Sprocket Gears
JNP242 TRANSFER CASE 21 - 305