Page 1873 of 2158
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. 6).
Fig. 3 Loosening Rear Retainer
Fig. 4 Rear Retainer Removal
Fig. 5 Loosening Rear Case
Fig. 6 Rear Case And Oil Pump Removal
JNP242 TRANSFER CASE 21 - 311
Page 1874 of 2158
(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; it is not repair-
able. Pumps are serviced only as an assembly.(16) Remove pickup tube O-ring from oil pump
(Fig. 9).
(17) Remove and discard oil pump seal.
(18) Remove magnet from front case.
(19) Remove drive sprocket snap ring (Fig. 10).
Fig. 7 Unseating Oil Screen
Fig. 8 Oil Pump/Pickup Tube/Screen Removal
Fig. 9 Pickup Tube O-Ring Removal
Fig. 10 Drive Sprocket Snap Ring Removal
21 - 312 NP242 TRANSFER CASEJ
Page 1875 of 2158
(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)
(24) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole (Fig. 14).
(25) Remove range fork lockpin with size number
one easy-out tool. Grip easy-out tool with locking pli-
ers and remove pin with counterclockwise, twist and
pull motion (Fig. 14).
fig. 11 Drive Sprocket And Chain Removal
Fig. 12 Removing Front Output Shaft
Fig. 13 Detent Component Removal
Fig. 14 Low Range Fork Lockpin Removal
JNP242 TRANSFER CASE 21 - 313
Page 1876 of 2158
(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 mainshaft (Fig. 17). Note position of
mode sleeve in fork and remove sleeve.
(29) Remove intermediate clutch shaft snap ring
(Fig. 18).
Fig. 15 Shift Rail Removal
Fig. 16 Mode Fork And Mainshaft Removal
Fig. 17 Mode Fork And Sleeve Removal
Fig. 18 Intermediate Clutch Shaft Snap Ring
Removal
21 - 314 NP242 TRANSFER CASEJ
Page 1877 of 2158
(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 differential needle bearings and both
needle bearing thrust washers from mainshaft.
Fig. 19 Clutch Shaft Thrust Ring Removal
Fig. 20 Intermediate Clutch Shaft Removal
Fig. 21 Differential Snap Ring Removal
Fig. 22 Differential Removal
JNP242 TRANSFER CASE 21 - 315
Page 1878 of 2158
(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).
Fig. 23 Disengaging Low Range Fork
Fig. 24 Low Range Fork And Hub Removal
Fig. 25 Shift Sector Position
Fig. 26 Sector Bushing And O-Ring Removal
21 - 316 NP242 TRANSFER CASEJ
Page 1879 of 2158
(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 input gear snap ring (Fig. 28).(42) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 29).
(43) Remove low range gear snap ring (Fig. 30).
Fig. 27 Front Bearing Retainer Removal
Fig. 28 Input Gear Snap Ring Removal
Fig. 29 Input And Low Range Gear Assembly
Removal
Fig. 30 Low Range Gear Snap Ring Removal/
Installation
JNP242 TRANSFER CASE 21 - 317
Page 1880 of 2158

(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 gear and front case as assembly.
(46) Remove oil seals from following components:
²rear retainer
²extension housing
²oil pump
²case halves
(47) Mark differential case halves for reference.
(48) Remove differential case bolts and separate
top case from bottom case. Use slots in case halves to
pry them apart (Fig. 33).
(49) Remove thrust washers and planet gears from
case pins (Fig. 34).(50) Remove mainshaft and sprocket gears from
bottom case (Fig. 35). Note gear position for reference
before separating them.
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 and allow
it to air dry. Use compressed air to remove solvent
residue from all oil feed passages and channels in
case halves.
Fig. 31 Low Range Gear Disassembly
Fig. 32 Inspecting Low Range Annulus Gear
Fig. 33 Separating Differential Case Halves
Fig. 34 Planet Gears And Thrust Washer Removal
21 - 318 NP242 TRANSFER CASEJ