2002 JEEP GRAND CHEROKEE fluid spec

(5) Align and position differential top case on bot-
tom case (Fig. 67). Align using scribe marks made at
disassembly.
(6) While holding differential case halves together,
invert the differential and start the differential case
bolts.
(7) Tighten differential case bolts to specified
torque.
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Assemble low range gear, input gear thrust
washers, input gear and input gear retainer (Fig. 68).
(2) Install low range gear snap ring (Fig. 69).
(3) Lubricate input gear and low range gears with
automatic transmission fluid.
(4) Start input gear shaft into front case bearing.
(5) Press input gear shaft into front bearing.
(6) Install new input gear snap ring (Fig. 70).
(7) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to seal surface
of front bearing retainer.
(8) Install front bearing retainer (Fig. 71). Tighten
retainer bolts to 16 ft. lbs. (21 N´m) torque.
SHIFT FORKS, SECTOR, AND MAINSHAFT
(1) Install the shift sector shaft o-ring and bush-
ing.
(2) Install shift sector.(3) Install new pads on low range fork, if neces-
sary.
(4) Assemble low range fork and sleeve.
Fig. 67 Differential Case Assembly
1 - TOP CASE
2 - BOTTOM CASE
3 - CASE ALIGNMENT MARKS
Fig. 68 Low Range And Input Gear Assembly
1 - THRUST WASHERS
2 - LOW RANGE GEAR
3 - INPUT GEAR
4 - RETAINER
Fig. 69 Install Low Range Gear Snap-Ring
1 - LOW RANGE GEAR SNAP-RING
21 - 300 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

REMOVAL
(1) Raise and support the vehicle.
(2) Disengage the transfer case position sensor
connector from the position sensor (Fig. 97).
(3) Remove the position sensor from the transfer
case.
INSTALLATION
(1) Inspect the o-ring seal on the transfer case
position sensor. Replace the o-ring if necessary.
(2) Install the transfer case position sensor into
the transfer case. Torque the sensor to 20-34 N´m
(15-25 ft.lbs.).
(3) Engage the transfer case position sensor con-
nector to the position sensor.
(4) Lower vehicle.
(5) Verify proper sensor operation.
REAR RETAINER BUSHING
AND SEAL - NV242HD
REMOVAL
(1) Raise vehicle.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the rear retainer seal.
(4) Using Remover 6957, remove bushing from
rear retainer (Fig. 98).
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in rear retainer
with fluid port in bushing aligned with slot in
retainer.
(3) Using Installer 8160, drive bushing into
retainer until installer seats against case (Fig. 99).
(4) Using Installer C-3995-A, install seal in rear
retainer (Fig. 100).
Fig. 97 Transfer Case Position Sensor and
Connector
1 - TRANSFER CASE POSITION SENSOR CONNECTOR
2 - TRANSFER CASE POSITION SENSOR
3 - TRANSFER CASE
4 - OUTPUT SPEED SENSOR CONNECTOR
Fig. 98 Rear Retainer Bushing Removal
1 - REMOVER 6957
2 - REAR RETAINER BUSHING
Fig. 99 Rear Retainer Bushing Install
1 - REAR RETAINER BUSHING
2 - INSTALLER 8160
21 - 312 TRANSFER CASE - NV242WJ
POSITION SENSOR (Continued)

(5) Install the rear propeller shaft. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(6) Verify proper fluid level.
(7) Lower vehicle.
SHIFT CABLE
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Disconnect the shift cable eyelet from the
transfer case shift lever (Fig. 101).
(4) Remove shift cable from the cable support
bracket.
(5) Lower vehicle.
(6) Remove any necessary console parts for access
to shift lever assembly and shift cable.(7) Disconnect cable at shift lever and shifter
assembly bracket (Fig. 102).
(8) Remove the nuts holding the shift cable seal
plate to the floor pan (Fig. 103).
(9) Pull cable through floor panel opening.
(10) Remove transfer case shift cable from vehicle.
INSTALLATION
(1) Route cable through hole in floor pan.
(2) Install seal plate to studs in floor pan.
(3) Install nuts to hold seal plate to floor pan (Fig.
103). Tighten nuts to 7 N´m (65 in.lbs.).
Fig. 100 Install Rear Retainer Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3995-A
Fig. 101 Transfer Case Shift Cable at Transfer Case
1 - TRANSFER CASE SHIFT LEVER
2 - TRANSFER CASE SHIFT CABLE
Fig. 102 Transfer Case Shift Cable at Shifter
1 - CLIP
2 - SHIFTER
3 - TRANSFER CASE SHIFT LEVER PIN
4 - TRANSFER CASE SHIFT CABLE
Fig. 103 Shift Cables at Floor Pan
1 - SEAL PLATES
2 - TRANSMISSION SHIFT CABLE
3 - TRANSFER CASE SHIFT CABLE
WJTRANSFER CASE - NV242 21 - 313
REAR RETAINER BUSHING AND SEAL - NV242HD (Continued)

TRANSFER CASE - NV247
TABLE OF CONTENTS
page page
TRANSFER CASE - NV247
DESCRIPTION........................315
OPERATION..........................316
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV247.......................316
REMOVAL............................317
DISASSEMBLY........................317
CLEANING...........................324
INSPECTION.........................324
ASSEMBLY...........................326
INSTALLATION........................335
SPECIFICATIONS
TRANSFER CASE - NV247.............336
SPECIAL TOOLS
TRANSFER CASE - NV247.............337FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................338
FRONT OUTPUT SHAFT SEAL
REMOVAL............................338
INSTALLATION........................338
REAR RETAINER BUSHING AND SEAL
REMOVAL............................339
INSTALLATION........................339
SHIFT CABLE
REMOVAL............................340
INSTALLATION........................340
TRANSFER CASE - NV247
DESCRIPTION
The NV247 (Fig. 1) is an on-demand 4-wheel drive
transfer case with two operating ranges and a neu-
tral position. Operating ranges are 4-high and 4-low.
The 4-low range is used for extra pulling power in
off-road situations.
TRANSFER CASE IDENTIFICATION
A circular I.D. tag is attached to the rear case of
each NV247 transfer case (Fig. 2). The tag indicates
the following information:
²Model number
²Serial number
²Assembly number
²Gear ratio
²Location of manufacture
The transfer case serial number also represents
the date of build.
Fig. 1 NV247 Transfer Case
Fig. 2 Transfer Case I.D. Tag
1 - FILL PLUG
2 - I.D. TAG
3 - DRAIN PLUG
WJTRANSFER CASE - NV247 21 - 315

(7) Install snap-ring to hold input/low range gear
into front bearing (Fig. 47).
(8) Clean gasket sealer residue from retainer and
inspect retainer for cracks or other damage.
(9) Applya3mm(1/8 in.) bead of Mopartgasket
maker or silicone adhesive to sealing surface of
retainer.
(10) Align cavity in seal retainer with fluid return
hole in front of case.
CAUTION: Do not block fluid return cavity on seal-
ing surface of retainer when applying MoparTgas-
ket maker or silicone adhesive sealer. Seal failure
and fluid leak can result.
(11) Install bolts to hold retainer to transfer case
(Fig. 48). Tighten to 21 N´m (16 ft. lbs.) of torque.SHIFT FORKS AND MAINSHAFT
(1) Install new sector shaft O-ring and bushing
(Fig. 49).
(2) Install shift sector (Fig. 50).
(3) Install locking clutch spring, locking clutch,
blockout spring, and range clutch sleeve, to main-
shaft as shown in (Fig. 51). Install snap ring.
(4) Install drive sprocket hub to mainshaft and
manually load the needle bearings.
(5) Install new pads on range fork, if necessary.
Fig. 47 Install Input Gear Snap-Ring
1 - INPUT GEAR
2 - SNAP-RING
Fig. 48 Install Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 49 Sector O-Ring And Bushing Installation
1 - SECTOR BUSHING
2 - O-RING
Fig. 50 Shift Sector Installation
1 - SHIFT SECTOR
21 - 330 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(6) Connect front propeller shaft and install rear
propeller shaft. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
(7) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(8) Install rear crossmember (Fig. 71) and skid
plate, if equipped. Tighten crossmember bolts to 41
N´m (30 ft. lbs.) torque.
(9) Remove transmission jack and support stand.
(10) Verify transfer case is in NEUTRAL. Connect
shift cable to transfer case range lever.
(11) Lower vehicle and verify transfer case shift
operation.
(12) Adjust the transfer case shift cable, if neces-
sary.
SPECIFICATIONS
TRANSFER CASE - NV247
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, crossmember 41-47 30.2-34.7 -
Plug, Detent 16-24 11.8-17.7 -
Plugs, drain/fill 20-34 15-25 -
Bolts, front brg. retainer 16-24 11.8-17.7 -
Bolts, case half 27-34 19.9-25 -
Nut, companion flange 122-176 90-130 -
Bolts, rear extension 27-34 19.9-25 -
Lock-nut, shift 27-34 19.9-25 -
Nuts, T-case mount stud 33-41 24.3-30.2 -
Fig. 71 Crossmember Installation
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
21 - 336 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

REAR RETAINER BUSHING
AND SEAL
REMOVAL
(1) Raise vehicle on hoist.
(2) Remove rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL)
(3) Using a suitable pry tool or slide-hammer
mounted screw, remove the rear retainer seal.
(4) Using Remover 6957, remove bushing from
rear retainer (Fig. 75).
INSTALLATION
(1) Clean fluid residue from sealing surface and
inspect for defects.
(2) Position replacement bushing in rear retainer
with fluid port in bushing aligned with slot in
retainer.
(3) Using Installer 8145, drive bushing into
retainer until installer seats against case (Fig. 76).
(4) Using Installer C-3995-A, install seal in rear
retainer (Fig. 77).
(5) Install rear propeller shaft. (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - INSTALLATION)
(6) Verify proper fluid level.
(7) Lower vehicle.
Fig. 74 Front Output Seal Installation
1 - INSTALLER 6952-A
2 - TRANSFER CASE
Fig. 75 Rear Retainer Bushing Removal
1 - REMOVER 6957
2 - REAR RETAINER BUSHING
Fig. 76 Rear Retainer Bushing Installation
1 - REAR RETAINER BUSHING
2 - INSTALLER 8145
Fig. 77 Install Rear Retainer Seal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-3995-A
WJTRANSFER CASE - NV247 21 - 339
FRONT OUTPUT SHAFT SEAL (Continued)

(11) Remove the bolts that secure the upper con-
denser and transmission cooler.
(12) Carefully lift the condenser out of the vehicle.
INSTALLATION
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
CAUTION: Before removing the condenser, note the
location of each of the radiator and condenser air
seals. These seals are used to direct air through the
condenser and radiator. The air seals must be rein-
stalled in their proper locations in order for the air
conditioning and engine cooling systems to per-
form as designed.
(1) Carefully position the condenser in the vehicle.
(2) Install the bolts that secure the upper con-
denser and transmission cooler.
(3) Remove the tape or plugs from the refrigerant
line fittings on the condenser inlet and the discharge
line. Connect the discharge line to the condenser
inlet. Tighten the retaining nut to 28 N´m (250 in.
lbs.).
(4) Remove the tape or plugs from the refrigerant
line fittings on the condenser outlet and the liquid
line. Connect the liquid line to the condenser outlet.
Tighten the retaining nut to 28 N´m (250 in. lbs.).
(5) Install the headlamp mounting module and
front fascia. Refer to Body for the procedure.
(6) Install the engine air filter inlet duct.
(7) Install the bolts that secure the radiator to the
upper crossmember.(8) Install the nuts that secure the hood latch and
brace to the upper crossmember.
(9) Install the headlamps in their mounts.
(10) Install the screws attaching the grille and
headlamp mounting module to the upper crossmem-
ber of the vehicle. Refer to Body for this and further
steps in the procedure.
(11) Evacuate and Recharge the refrigerant sys-
tem. (Refer to 24 - HEATING & AIR CONDITION-
ING/PLUMBING - STANDARD PROCEDURE -
REFRIGERANT SYSTEM EVACUATE) (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT SYS-
TEM CHARGE)
(12) Connect the battery negative cable.
NOTE: If the condenser is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING/REFRIGERANT OIL - DESCRIPTION)
A/C DISCHARGE LINE
REMOVAL
REMOVAL - 2.7L TURBO DIESEL
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE FRONT OF THIS SECTION BEFORE
PERFORMING THE FOLLOWING OPERATION.
(Refer to 24 - HEATING & AIR CONDITIONING/
PLUMBING - WARNING) (Refer to 24 - HEATING &
AIR CONDITIONING/PLUMBING - CAUTION)
(1) Disconnect and isolate the negative battery
cable.
(2) Recover the refrigerant system. (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
STANDARD PROCEDURE - REFRIGERANT
RECOVERY)
(3) Remove both headlamps from the vehicle. Refer
to Lamps/Lighting for the procedure.
(4) Remove the a/c high pressure transducer(Refer
to 24 - HEATING & AIR CONDITIONING/CON-
TROLS/A/C PRESSURE TRANSDUCER - REMOV-
AL).
(5) Remove the front fascia from the vehicle. Refer
to Front Fascia for the procedure (Fig. 7).
(6) Remove the refrigerant line retaining fastener
from the condenser inlet fitting. Remove the line and
cap the condenser inlet tube to prevent contamina-
tion of the system.
WJPLUMBING 24 - 63
A/C CONDENSER (Continued)