1995 JEEP CHEROKEE Service Repair Manual

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Page 1689 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (13) Slide oil screen (Fig. 7) out of case pocket.
(14) Remove oil pump, pickup tube and oil screen
from rear case (Fig. 8).
(15) Remove pickup tube and screen from pump.
Do not disassemble oil pump;

Page 1690 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (20) Remove drive sprocket and chain (Fig. 11).
(21) Remove front output shaft (Fig. 12).(22) Remove transfer case shift lever nut and lever.
(23) Remove shift detent plug, spring and pin (Fig.
13)
(2

Page 1691 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (26) Remove shift rail by pulling it straight up and
out of fork (Fig. 15).
(27) Remove mode fork and mainshaft as assembly
(Fig. 16).
(28) Remove mode shift sleeve and mode fork as-
sembly from mains

Page 1692 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (30) Remove clutch shaft thrust ring (Fig. 19).
(31) Remove intermediate clutch shaft (Fig. 20).(32) Remove differential snap ring (Fig. 21).
(33) Remove differential (Fig. 22).
(34) Remove differenti

Page 1693 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (35) Slide low range fork pin out of shift sector slot
(Fig. 23)
(36) Remove low range fork and hub (Fig. 24).(37) Remove shift sector (Fig. 25).
(38) Remove shift sector bushing and O-ring (Fig.
26).

Page 1694 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (39) Remove front bearing retainer bolts.
(40) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 27). Position
screwdriver in slots cast into retainer.
(41) Remove inp

Page 1695 of 2198

JEEP CHEROKEE 1995 Service Repair Manual (44) Remove input gear retainer, thrust washers
and input gear from low range gear (Fig. 31).
(45) Inspect low range annulus gear (Fig. 32).
Gear is not a serviceable component. If dam-
aged, replace

Page 1696 of 2198

JEEP CHEROKEE 1995 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

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 transfer case components with auto-
matic transmission fluid or petroleum jelly (where in-
dicated) 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 snap ring that retains front output
shaft front bearing in case (Fig. 36). Then remove
bearing. Use hammer handle, or hammer and brass
punch to tap bearing out of case.
(3) Install new front output shaft bearing with Tool
Handle C-4171 and Installer 8033A (Fig. 37).
(4) Install front bearing snap ring (Fig. 36).
(5) Install new front output shaft oil seal as fol-
lows:(a) Tap seal into bore until flush with upper edge
of case bore. Use suitable size installer tool to start
seal into place (Fig. 38).
(b) Seat seal 2.03 to 2.5 mm (0.080 to 0.100 in.)
belowtop edge of seal bore in front case (Fig. 39).
This is correct final seal position. Use suitable size
installer tool or blunt punch to final-seat seal.
Check seal depth with a dial caliper or depth mi-
crometer.
CAUTION: Be sure the front output seal is seated
below the top edge of the case bore as shown (Fig.
39). The seal could work loose if not seated to the
recommended depth.
(6) Remove input gear bearing with Tool Handle
C-4171 and Remover C-4210 (Fig. 40).
Fig. 35 Mainshaft And Sprocket Gear RemovalFig. 36 Front Output Shaft Front Bearing Snap Ring
Removal
Fig. 37 Front Output Shaft Front Bearing Installation
JNP242 TRANSFER CASE 21 - 319

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