1994 JEEP CHEROKEE oil

(12) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 35).
(13) Install input gear snap ring (Fig. 36).
(14) Lubricate input gear with automatic transmis-
sion fluid.
(15) Start input gear in front bearing.
(16) Press input gear into front bearing (Fig. 36).
CAUTION: Use a proper size tool to press the input
gear into the front bearing. An incorrect tool could
push the input gear pilot bearing too far into the
gear bore (Fig. 45). Also, do not press against the
end surfaces of the low range gear. The gear case
and thrust washers could be damaged.
(17) Install input gear snap ring (Fig. 37).
(18) Install new oil seal in front bearing retainer.
(19) Apply 3 mm (1/8 in.) wide bead of Mopar Gas-
ket Maker, silicone adhesive/sealer, or Loctite 518 to
front bearing retainer seal surface (Fig. 38).
(20) Install front bearing retainer on front case (Fig.
22). Tighten retainer bolts to 21 Nzm (16 ft. lbs.) torque.
(21) Install new sector shaft O-ring and bushing
(Fig. 39).
Fig. 37 Installing Input Gear Snap Ring
Fig. 38 Applying Sealer To Front Bearing Retainer
Fig. 39 Installing Sector O-Ring And Bushing
Fig. 35 Input And Low Range Gear Assembly
Fig. 36 Input And Low Range Gear Installation
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(22) Install shift sector in the case (Fig. 40).
(23) Install range lever and lever attaching nut on
shift sector. Tighten attaching nut to 30 Nzm (22 ft.
lbs.) torque.
(24) Install detent plunger, spring and plug (Fig.
41). Tighten plug to 20 Nzm (15 ft. lbs.) torque.
(25) Inspect range fork pads (Fig. 42). Be sure
pads are secure and in position.
(26) Assemble range fork and shift hub (Fig. 43).
(27) Engage range fork pin in sector slot (Fig. 44).
(28) If drive sprocket bearings are to be replaced,
remove and install them as follows:
(a) Press both bearings out of sprocket simulta-
neously with Remover Tool C-4667, or 5066 and
Tool Handle C-4171 (Fig. 45).
(b) Before installing new bearings, refer to Fig-
ure 46 and note correct bearing position in
sprocket. Bearings must be also be installed in
proper sequence. Install front bearing first and
rear bearing last.CAUTION: Do not press the bearings any farther
into the sprocket than indicated in Figure 46. The
bearings could block the mainshaft oil feed hole if
pressed too deeply into the sprocket.
Fig. 42 Range Fork Pads
Fig. 43 Assembling Range Fork And Shift Hub
Fig. 44 Seating Range Fork In Sector
Fig. 40 Installing Shift Sector
Fig. 41 Installing Detent Plunger, Spring And Plug
JNP231 TRANSFER CASE 21 - 285

(b) Seat new bearing in rear case with Tool Han-
dle C-4171 and Bearing Installer 5063 (Fig. 56).
(40) Install new seal in oil pump feed housing (Fig.
57).(41)If new oil pump is being installed, pro-
ceed to step (43). If original pump was only dis-
assembled for cleaning and inspection, proceed
to step (42).
(42) Assemble oil pump. Lubricate and install two
gears in gear housing. Align and install feed housing
on gear housing (Fig. 58). Install and tighten oil
pump screws to 2 Nzm (14 in. lbs.) torque.
(43) Install new pickup tube O-ring in oil pump
(Fig. 59).
(44) Insert oil pickup tube in oil pump. Then at-
tach oil screen and connecting hose to pickup tube
(Fig. 60).
(45) Install assembled oil pump, pickup tube and
screen in rear case. Be sure screen is seated in case
slot as shown (Fig. 60).
Fig. 55 Removing Front Output Shaft Rear Bearing
Fig. 56 Installing Front Output Shaft Rear Bearing
Fig. 57 Installing Oil Pump Feed Housing Seal
Fig. 58 Oil Pump Components
Fig. 59 Pickup Tube O-Ring Installation
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(46) Install magnet in front case.
(47) 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.
(48) Align and install rear case on front case (Fig.
61). Be sure case locating dowels are in place and
that mainshaft splines are engaged in oil pump inner
gear.(49) Install and tighten front case-to-rear case at-
taching bolts to 41 Nzm (30 ft. lbs.) torque.Be sure
to install a washer under each bolt used at case
dowel locations.
(50) Install mainshaft rear bearing in rear retainer
(Fig. 62). Tap old bearing out of retainer with ham-
mer and brass drift. Then install new bearing with
Tool Handle C-4171 and Installer 5064.
(51) Apply 3 mm (1/8 in.) wide bead of Mopar gas-
ket maker, silicone adhesive sealer, or Loctite 518 to
flange surface of rear retainer.
(52) Install locating dowel in rear retainer and in-
stall retainer on case. Tighten retainer bolts to 24
Nzm (18 ft. lbs.) torque.
(53) Install new rear bearing snap ring (Fig. 63).
Lift mainshaft slightly to seat snap ring in shaft
groove.
(54) Remove extension housing seal if not removed
previously.
Fig. 60 Pickup Tube, Oil Screen And Pump
Installation
Fig. 61 Installing Rear Case On Front Case
Fig. 62 Installing Mainshaft Rear Bearing In Rear
Retainer
Fig. 63 Installing Rear Bearing Snap Ring
JNP231 TRANSFER CASE 21 - 289

(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
JNP242 TRANSFER CASE 21 - 299

(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

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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