1994 JEEP CHEROKEE Service Repair Manual

(50) Install front output shaft (Fig. 73).
(51) Install drive chain (Fig. 73). Engage chain
with front output shaft sprocket teeth.
(52) Install drive sprocket (Fig. 73).
(53) Engage drive sprocket teeth with chain. Then
engage sprocket splines with mainshaft splines.
(54) Install drive sprocket snap ring (Fig. 74).
(55) Replace front output shaft rear bearing. Re-
move bearing with internal puller and slide hammer
(Fig. 75). Install new bearing with bearing driver
tools (Fig. 75). Lubricate bearing after installation.(56) Assemble oil pump (Fig. 76). Replace any
pump components that are worn or damaged.
Fig. 73 Installing Drive Chain And Sprocket
Fig. 74 Installing Drive Sprocket Snap Ring
Fig. 75 Installing Front Output Shaft Rear Bearing
Fig. 76 Oil Pump Assembly
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(57) Install new seal in oil pump feed housing (Fig.
77).
(58) Install new pickup tube O-ring in oil pump
(Fig. 78).
(59) Insert oil pickup tube in oil pump and attach
oil screen and connecter hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 79). Be sure screen is seated in case slot as
shown.
(60) Install magnet in front case pocket (Fig. 80).(61) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of front case.
(62) 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.
(63) Install and tighten the front case-to-rear case
bolts to 41 Nzm (30 ft. lbs.) torque.Be sure to in-
stall a washer under each of the bolts used at
the case dowel locations.
(64) Tap rear retainer bearing out of retainer with
hammer and brass drift.
(65) Install new bearing in rear retainer with
driver tools (Fig. 81).
(66) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of rear retainer.
Fig. 77 Installing Oil Pump seal
Fig. 78 Installing Pickup Tube O-Ring
Fig. 79 Installing Oil Screen And Pickup Tube
Fig. 80 Installing Case Magnet
JNP242 TRANSFER CASE 21 - 315

(67) Install locating dowel in rear retainer (if re-
moved) and install the retainer on the case. Tighten
the retainer bolts to 41 Nzm (30 ft. lbs.) torque.
(68) Install new rear bearing snap ring (Fig. 82).
Lift mainshaft slightly to seat the snap ring if neces-
sary.
(69) Remove extension housing seal if not removed
previously.
(70) Replace extension housing bushing with driver
tools (Fig. 83).(71) Install new extension housing oil seal (Fig.
84).
Fig. 83 Replacing Extension Housing Bushing
Fig. 84 Replacing Extension Housing Seal
Fig. 81 Installing Rear Bearing In Retainer
Fig. 82 Installing Rear Bearing Snap Ring
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(72) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
seal surface of extension housing.
(73) Install extension housing on case. Tighten
housing bolts to 41 Nzm (30 ft. lbs.) torque.
(74) Install front yoke. Secure yoke with new seal
washer and nut. Tighten nut to 149 Nzm (110 ft. lbs.)
torque.
(75) Install new gasket on vacuum switch and in-
stall switch in the case. Tighten switch to 27 Nzm (20
ft. lbs.) torque.
(76) Install speedometer components (Fig. 85).
(77) Install and tighten drain plug to 47 Nzm (35
ft. lbs.) torque.
(78) After installing transfer case, refill with rec-
ommended transmission fluid.
(79) Tighten fill plug to 47 Nzm (35 ft. lbs.) torque.
(80) Adjust transfer case shift linkage.
Fig. 85 Speedometer Components
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LEGEND FOR NP242 TRANSFER CASE
JNP242 TRANSFER CASE 21 - 319

TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TORQUE SPECIFICATIONSÐ
AX 15 MANUAL TRANSMISSION
21 - 320 TRANSMISSION/TRANSFER CASE SPECIFICATIONSJ

SELECTIVE SNAP RING CHARTÐAX 15 MANUAL TRANSMISSION
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 321