1994 JEEP CHEROKEE Service Repair Manual

Inspect the differential gears, thrust washers and
case halves. Replace the mainshaft gear if the gear
teeth or the brass ring on the underside of the gear
are damaged. Replace the differential as an assembly
if the gears, case halves, or the pins in the lower case
half are damaged.
Inspect the case halves, extension housing and re-
tainers for cracks, porosity, or damaged sealing sur-
faces. Inspect the shafts, gears, chain and shift
components for wear or damage.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam-
aged bearings as outlined in the assembly section.
TRANSFER CASE ASSEMBLY
(1) Lubricate the transfer case components with
automatic transmission fluid or petroleum jelly
(where indicated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Be sure re-
placement bearings do not block these feed holes.
(2) Remove the front output shaft, front bearing
snap ring (Fig. 42).(3) Remove the old bearing and install the new
bearing with a driver handle and installer tool (Fig.
43).
(4) Install the front bearing snap ring (Fig. 42).
(5) Install new front output shaft oil seal (Fig. 44).
Fig. 42 Removing/Installing Front Output Shaft
Front Bearing Snap Ring
Fig. 43 Replacing Output Shaft Front Bearing
Fig. 44 Installing Front Output Shaft Seal
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(6) Press input gear bearing out of front case with
driver tool and shop press (Fig. 45).
(7) Install the snap ring on the new bearing.
(8) Install the new input gear bearing with a shop
press and wood block. Install the bearing far enough
to seat the snap ring against the case (Fig. 46).(9) Remove input gear pilot bearing with slide
hammer and internal puller (Fig. 47).
(10) Install new pilot bearing with driver tools
(Fig. 48).
Fig. 45 Removing Input Gear Bearing
Fig. 46 Seating Input Gear Bearing
Fig. 47 Removing Input Gear Pilot Bearing
Fig. 48 Installing Input Gear Pilot Bearing
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(11) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 49).
(12) Install low range gear snap ring (Fig. 50).
(13) Lubricate input gear and low range gears with
automatic transmission fluid.
(14) Start the input gear shaft into the front case
bearing.
(15) Press the input gear shaft into the front bear-
ing.CAUTION: Be sure the input gear installer tool is
the proper size. The wrong size tool could push the
input gear pilot bearing too far into the gear bore
(Fig. 51). Also, do not press against the end sur-
faces of the low range gear. The gear case and
thrust washers could be damaged.
(16) Install new input gear snap ring (Fig. 52).
Fig. 49 Low Range And Input Gear Assembly
Fig. 50 Install Low Range Gear Snap Ring
Fig. 51 Input Gear Installation
Fig. 52 Install Input Gear Snap Ring
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(17) Install new seal in front bearing retainer (Fig.
53).
(18) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker. silicone adhesive sealer, or Loctite 518 to
seal surface of front bearing retainer.
(19) Install the front bearing retainer (Fig. 54).
Tighten the retainer bolts to 16 ft. lbs. (21 Nzm)
torque.(20) Install new sector shaft O-ring and bushing
(Fig. 55).
(21) Install the shift sector.
(22) Install new pads in low range fork (Fig. 56).
(23) Assemble low range fork and hub (Fig. 56).
Fig. 55 Installing Sector O-Ring And Bushing
Fig. 56 Assembling Low Range Fork And Hub
Fig. 53 Install Front Bearing Retainer Seal
Fig. 54 Installing Front Bearing Retainer
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(24) Position low range fork and hub in case. Be
sure low range fork pin is engaged in the shift sector
slot (Fig. 57).
(25) Lubricate differential components with auto-
matic transmission fluid.
(26) Install sprocket gear in differential bottom
case (Fig. 58).(27) Install differential planet gears and new
thrust washers (Fig. 59).Be sure thrust washers
are installed at top and bottom of each planet
gear.
(28) Install differential mainshaft gear (Fig. 59).
(29) Align and position differential top case on bot-
tom case (Fig. 60). Align using scribe marks made at
disassembly.
(30) Install and tighten the differential case bolts
to specified torque.
Fig. 57 Positioning Low Range Fork
Fig. 58 Installing Differential Sprocket Gear
Fig. 59 Installing Mainshaft And Planet Gears
Fig. 60 Differential Case Assembly
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(31) Install first mainshaft bearing spacer on
mainshaft (Fig. 61).
(32) Install bearing rollers on mainshaft (Fig. 61).
Coat bearing rollers with generous quantity of
petroleum jelly to hold them in place.
(33) Install remaining bearing spacer on mainshaft
(Fig. 61). Do not displace any bearings while installing
spacer.
(34) Install the differential (Fig. 62).Do not dis-
place the mainshaft bearings when installing
the differential.(35) Install the differential snap ring (Fig. 63).
(36) Install the intermediate clutch shaft (Fig. 64).
Fig. 61 Installing Mainshaft Bearing Rollers and
Spacers
Fig. 62 Differential Installation
Fig. 63 Installing Differential Snap Ring
Fig. 64 Installing Intermediate Clutch Shaft
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(37) Install clutch shaft thrust washer (Fig. 65).
(38) Install clutch shaft snap ring (Fig. 66).
(39) Inspect mode fork assembly (Fig. 67). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 67). Replace
worn, damaged components.(40) Install mode sleeve in mode fork (Fig. 68).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
Fig. 65 Installing Clutch Shaft Thrust Washer
Fig. 66 Installing Clutch Shaft Snap Ring
Fig. 67 Inspect Mode Fork Assembly
Fig. 68 Installing Mode Fork And Sleeve
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(41) Install mode fork and mainshaft assembly in
case (Fig. 69). Rotate mainshaft slightly to engage
shaft with low range gears.
(42) Rotate mode fork pin into shift sector slot.
(43) Install shift rail (Fig. 70).Be sure rail is
seated in both shift forks.
(44) Rotate shift sector to align lockpin hole in low
range fork with access hole in case.(45) Insert an easy-out in range fork lockpin to
hold it securely for installation (Fig. 71).Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(46) Insert lockpin through access hole and into
shift fork (Fig. 71). Then remove the easy-out and
seat the pin with pin punch.
(47) Install plug in lockpin access hole.
(48) Install transfer case shift lever and attaching
nut. Tighten nut to 30 Nzm (22 ft. lbs.) torque.
(49) Install detent plunger, detent spring and de-
tent plug in the case (Fig. 72).
Fig. 69 Installing Mainshaft And Mode Fork
Fig. 70 Installing Shift Rail
Fig. 71 Installing Low Range Fork Lockpin
Fig. 72 Installing Detent Pin, Spring And Plug
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