2002 JEEP GRAND CHEROKEE Workshop Manual

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Page 1809 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (13) Slide low range fork pin out of shift sector
slot.
(14) Remove low range fork and sleeve (Fig. 35).
(15) Remove shift sector.(16) Remove the shift sector shaft bushing and
o-ring (Fig. 36).
INPUT

Page 1810 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (4) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 39).
(5) Remove low range gear snap-ring (Fig. 40).
(6) Remove input gear retainer, thrust washers
an

Page 1811 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (7) Inspect low range annulus gear (Fig. 42).Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oil seals from following components:
²front bearing r

Page 1812 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part that is

Page 1813 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 47). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear

Page 1814 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 49). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut an

REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 49). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut and seal washer as neither part should be
reused.
Inspect the shaft threads, sprocket teeth, and bear-
ing surfaces. Minor nicks on the teeth can be
smoothed with an oilstone. Use 320-400 grit emery to
smooth minor scratches on the shaft bearing sur-
faces. Rough threads on the shaft can be chased if
necessary. Replace the shaft if the threads are dam-
aged, bearing surfaces are scored, or if any sprocket
teeth are cracked or broken.
Examine the drive chain and shaft bearings.
Replace the chain and both sprockets if the chain is
stretched, distorted, or if any of the links bind.
Replace the bearings if rough, or noisy.
LOW RANGE ANNULUS GEAR
Inspect annulus gear condition carefully. The gear
is only serviced as part of the front case. If the gear
is damaged, it will be necessary to replace the gear
and front case as an assembly. Do not attempt to
remove the gear (Fig. 50)
FRONT-REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and dam-
age. Clean the sealing surfaces with a scraper and
3M all purpose cleaner. This will ensure proper
sealer adhesion at assembly. Replace the input
retainer seal; do not reuse it.Check case condition. If leaks were a problem, look
for gouges and severe scoring of case sealing sur-
faces. Also make sure the front case mounting studs
are in good condition.
Check the front case mounting studs and vent
tube. The tube can be secured with LoctiteŸ 271 or
680 if loose. The stud threads can be cleaned up with
a die if necessary. Also check condition of the fill/
drain plug threads in the rear case. The threads can
be repaired with a thread chaser or tap if necessary.
Or the threads can be repaired with HelicoilŸ stain-
less steel inserts if required.
OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the
pump if any part appears to be worn or damaged. Do
not disassemble the pump as individual parts are not
available. The pump is only available as a complete
assembly. The pickup screen, hose, and tube are the
only serviceable parts and are available separately.
ASSEMBLY
Lubricate transfer case components with automatic
transmission fluid or petroleum jelly (where indi-
cated) during assembly.
CAUTION: The bearing bores in various transfer
case components contain oil feed holes. Make sure
replacement bearings do not block the holes.
Fig. 49 Seal Contact Surface Of Yoke Slinger
1 - FRONT SLINGER (PART OF YOKE)
2 - SEAL CONTACT SURFACE MUST BE CLEAN AND SMOOTH
Fig. 50 Low Range Annulus Gear
1 - FRONT CASE
2 - LOW RANGE ANNULUS GEAR
WJTRANSFER CASE - NV242 21 - 295
TRANSFER CASE - NV242 (Continued)

Page 1815 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual BEARING AND SEAL
(1) Remove snap-ring that retains front output
shaft front bearing in case (Fig. 51). Then remove
bearing. Use hammer handle, or hammer and brass
punch to tap bearing out of case.
(2)

Page 1816 of 2199

JEEP GRAND CHEROKEE 2002 WJ / 2.G Workshop Manual (6) Remove input gear bearing with Tool Handle
C-4171 and Remover C-4210 (Fig. 55).
(7) Install snap-ring on new input gear bearing.
(8) Install new input gear bearing with Tool Han-
dle C-4171 and Re

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