Page 1705 of 2198

(55) Replace front output shaft rear bearing (Fig.
70). Remove bearing with internal puller and slide
hammer. Install new bearing with Tool Handle
C-4171 and Installer 5066. Lubricate bearing after
installation.
(56) Install new seal in oil pump feed housing with
Special Tool 7888 (Fig. 71).
(57) Install new pickup tube O-ring in oil pump
(Fig. 72).(58) 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. 73). Be sure screen is seated in case slot as
shown.
(59) Install magnet in front case pocket (Fig. 74).
(60) 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.
(61) 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.
Fig. 70 Front Output Shaft Rear Bearing Installation
Fig. 71 Oil Pump Seal Installation
Fig. 72 Pickup Tube O-Ring Installation
Fig. 73 Oil Screen And Pickup Tube Installation
21 - 328 NP242 TRANSFER CASEJ
Page 1706 of 2198

(62) Install and tighten front case-to-rear case
bolts to 41 Nzm (30 ft. lbs.) torque.Be sure to in-
stall a washer under each bolt used at case
dowel locations.
(63) Tap rear retainer bearing out of retainer with
hammer and brass drift.
(64) Install bearing in rear retainer with Driver
Handle C-4171 and Installer 5064 (Fig. 75).
(65) 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.
(66) Install locating dowel in rear retainer (if re-
moved) and install retainer on the case. Tighten re-
tainer bolts to 41 Nzm (30 ft. lbs.) torque.(67) Install new rear bearing snap ring (Fig. 76).
Lift mainshaft slightly to seat snap ring if necessary.
(68) Remove extension housing seal if not removed
previously.
(69) Replace extension housing bushing (Fig. 77).
²Use Tools C-4171 and 7889-A to remove bushing
²Use Tools C-4171 and 5066 to install bushing
Fig. 74 Installing Case Magnet
Fig. 75 Installing Rear Bearing In Retainer
Fig. 76 Rear Bearing Snap Ring Installation
JNP242 TRANSFER CASE 21 - 329
Page 1707 of 2198
(70) Install new extension housing oil seal with Spe-
cial Tool 7891 (Fig. 78).
(71) 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.
(72) Install extension housing on case. Tighten
housing bolts to 41 Nzm (30 ft. lbs.) torque.(73) Install front yoke. Secure yoke with new seal
washer and nut. Tighten nut to 149 Nzm (110 ft. lbs.)
torque.
(74) Install new gasket on vacuum switch and in-
stall switch in case. Tighten switch to 27 Nzm (20 ft.
lbs.) torque.
(75) Install speedometer components.
(76) Install and tighten drain plug to 47 Nzm (35
ft. lbs.) torque.
(77) After installing transfer case, refill with rec-
ommended lubricant.
(78) Tighten fill plug to 47 Nzm (35 ft. lbs.) torque.
(79) Adjust transfer case shift linkage.
Fig. 77 Extension Housing Bushing Replacement
Fig. 78 Seating Extension Housing Seal
21 - 330 NP242 TRANSFER CASEJ
Page 1708 of 2198
NP242 TRANSFER CASE
JNP242 TRANSFER CASE 21 - 331
Page 1709 of 2198
LEGEND FOR NP242 TRANSFER CASE
21 - 332 NP242 TRANSFER CASEJ
Page 1710 of 2198
TRANSMISSION/TRANSFER CASE SPECIFICATIONS
TORQUE SPECIFICATIONSÐMANUAL
TRANSMISSION
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 333
Page 1711 of 2198
SELECTIVE SNAP RING CHARTÐAX 15 MANUAL TRANSMISSION
21 - 334 TRANSMISSION/TRANSFER CASE SPECIFICATIONSJ
Page 1712 of 2198
30RH/32RH GENERAL SPECIFICATIONS
30RH/32RH SNAP RING/THRUST WASHER/THRUST PLATE SPECIFICATIONS
JTRANSMISSION/TRANSFER CASE SPECIFICATIONS 21 - 335