1995 JEEP CHEROKEE Service Repair Manual

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Page 1665 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
(16) If transfer case was removed for overhaul, re-
move damper from rear retainer

Page 1666 of 2198

JEEP CHEROKEE 1995 Service Repair Manual TRANSFER CASE DISASSEMBLY AND OVERHAUL
Two versions of the NP231 are used in current
models. One version retains the synchronizer
components used in previous years. A newly intro-
duced version does n

Page 1667 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (11) Remove oil pump and rear case as an assem-
bly (Fig. 5).
(12) Slide oil pickup tube screen out of case pocket.
(13) Remove oil pump and pickup tube as assembly
(Fig. 6).(14) Disconnect screen fro

Page 1668 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (18) Tap front output shaft upward with rawhide
mallet to free it from shaft bearing.
(19) Remove front output shaft and drive chain
(Fig. 10).
(20) Remove mainshaft, mode fork and shift rail as
assem

Page 1669 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (24) Remove hub from mainshaft. On synchro mod-
els, also remove synchro stop ring (Fig. 15).
(25) Remove drive sprocket (Fig. 16).
(26) Slide range fork pin out of shift sector (Fig.
17).
(27) Remove

Page 1670 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (31) Remove shift detent plunger, spring and plug
(Fig. 21). Remove O-ring from plug after removal.
(32) Turn front case over and remove front bearing
retainer bolts (Fig. 22).
(33) Remove front beari

Page 1671 of 2198

JEEP CHEROKEE 1995 Service Repair Manual OVERHAUL 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 solv

OVERHAUL 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. Shake ex-
cess solvent from screen and allow it air dry. Use
compressed air to remove solvent residue from all oil
feed passages and channels in the case halves.
Inspect the splines and bearing surfaces on the
both shafts. Replace either shaft as necessary if wear,
or damage is evident.
Check condition of the shift forks, fork pads and
shift rail. Minor scratches/nicks on the rail can be
smoothed with 320/400 grit emery cloth. Replace the
mode fork pads if worn. Replace the range fork if the
pads are worn, missing, or damaged.
On synchro equipped models, inspect the synchro
sleeve, hub, struts, springs, and the stop ring. Re-
place worn, or damaged parts as necessary.
Do not attempt to salvage and reuse snap rings
that were bent, or distorted. It is recommended that
all snap rings be replaced during overhaul.Replace the front yoke nut as it should not be re-
used. Also replace the rubber seal if worn, cut, or
torn.
Inspect the low range annulus gear (Fig. 28).If
the gear is damaged, replace the gear and front
case as an assembly. Do not attempt to remove
the gear.
Inspect the case halves, extension housing and re-
tainers for cracks, porosity, or damaged sealing sur-
faces.
Inspect the drive sprockets and drive chain care-
fully. Replace the sprockets if worn, chipped, or
cracked. Also replace the chain if distorted, binds at
any point, or is stretched.
Replace the oil pump if any pump part is worn or
damaged. Do not disassemble the pump as parts are
not available separately. The pump is only available
as an assembly.
Inspect all of the transfer case bearings for wear,
roughness, pitting, or galling. Replace worn or dam-
aged bearings as outlined in the transfer case assem-
bly procedures.
Clean the sealing (mating) surfaces of the case
halves, retainer and extension with a scraper, a wire
brush and 3M All Purpose cleaning solvent. These
surfaces must be clean in order for the sealer to ad-
here properly.
TRANSFER CASE 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.
In addition, the drive sprocket, synchro hub and
sleeve are different for non-synchro and synchro
models. Do not interchange these parts. Do not in-
stall synchro struts or a stop ring in a non-synchro
model; this will cause the drive sprocket to bind on
the shaft and hub.
Fig. 26 Removing Low Range Gear Snap Ring
Fig. 27 Input And Low Range Gear Components
Fig. 28 Low Range Annulus Gear Location
21 - 294 NP231 TRANSFER CASEJ

Page 1672 of 2198

JEEP CHEROKEE 1995 Service Repair Manual FRONT CASE ASSEMBLY
(1) Lubricate components with automatic transmis-
sion fluid (or petroleum jelly where indicated) during
assembly.
(2) Remove front output shaft seal from front case
with crowfoot

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