2002 JEEP GRAND CHEROKEE Bus

OPERATION
REACTION PLANETARY GEARTRAIN
The reaction planetary carrier and reverse sun
gear of the reaction planetary geartrain are a single
component which is held by the 2C clutch when
required. The reaction annulus gear is a stand alone
component that can be driven by the reverse clutch
or held by the 4C clutch. The reaction sun gear is
driven by the overdrive clutch.
REVERSE PLANETARY GEARTRAIN
The reverse planetary geartrain is the middle of
the three planetary sets. The reverse planetary car-
rier can be driven by the overdrive clutch as
required. The reverse planetary carrier is also
splined to the input annulus gear, which can be held
by the low/reverse clutch. The reverse planetary
annulus, input planetary carrier, and output shaft
are all one piece.
INPUT PLANETARY GEARTRAIN
The input sun gear of the input planetary
geartrain is driven by the underdrive clutch.
DISASSEMBLY
(1) Remove the snap-ring holding the input annu-
lus into the input carrier (Fig. 104).
(2) Remove the input annulus from the input car-
rier (Fig. 104).
(3) Remove the number 9 bearing from the reverse
planetary carrier. Note that this planetary carrier
has four pinion gears.
(4) Remove the reverse planetary gear carrier (Fig.
104).
(5) Remove the number 10 bearing from the input
sun gear (Fig. 104).
(6) Remove the input sun gear from the input car-
rier (Fig. 104).
(7) Remove the number 11 bearing from the input
carrier (Fig. 104).
CLEANING
Clean the planetary components in solvent and dry
them with compressed air.
INSPECTION
Check sun gear and driving shell condition.
Replace the gear if damaged or if the bushings are
scored or worn. The bushings are not serviceable.
Fig. 104 Reverse/Input Planetary Carrier Assembly
1 - SNAP-RING 5 - INPUT PLANETARY CARRIER
2 - BEARING NUMBER 10 6 - INPUT SUN GEAR
3 - BEARING NUMBER 11 7 - REVERSE PLANETARY CARRIER
4 - INPUT ANNULUS
21 - 260 AUTOMATIC TRANSMISSION - 545RFEWJ
PLANETARY GEARTRAIN (Continued)

TRANSFER CASE - NV242
TABLE OF CONTENTS
page page
TRANSFER CASE - NV242
DESCRIPTION........................280
OPERATION..........................281
DIAGNOSIS AND TESTING - TRANSFER
CASE - NV242.......................281
REMOVAL............................282
DISASSEMBLY........................282
CLEANING...........................292
INSPECTION.........................293
ASSEMBLY...........................295
INSTALLATION........................307
SPECIFICATIONS
TRANSFER CASE - NV242.............308
SPECIAL TOOLS
TRANSFER CASE - NV242.............308
FLUID
STANDARD PROCEDURE - FLUID DRAIN/
REFILL............................310FRONT OUTPUT SHAFT SEAL
REMOVAL............................310
INSTALLATION........................310
POSITION SENSOR
DESCRIPTION........................311
OPERATION..........................311
REMOVAL............................312
INSTALLATION........................312
REAR RETAINER BUSHING AND SEAL -
NV242HD
REMOVAL............................312
INSTALLATION........................312
SHIFT CABLE
REMOVAL............................313
INSTALLATION........................313
TRANSFER CASE - NV242
DESCRIPTION
The NV242 is a full transfer case (Fig. 1). It pro-
vides full time 2-wheel, or 4-wheel drive operation.
A differential in the transfer case is used to control
torque transfer to the front and rear axles. A low
range gear provides increased low speed torque capa-
bility for off road operation. The low range provides a
2.72:1 reduction ratio.
The geartrain is mounted in two aluminum case
halves attached with bolts. The mainshaft front and
rear bearings are mounted in aluminum retainer
housings bolted to the case halves.
TRANSFER CASE IDENTIFICATION
Two versions of the NV242 are used in the WJ
vehicles, NV242LD and NV242HD. The two transfer
cases can be distinguished from one another by the
rear output shaft retainer. The NV242LD uses a rub-
ber boot to cover the rear output shaft, while the
NV242HD uses a cast aluminum housing. Other than
this difference, the two transfer cases are serviced
the same.
A circular ID tag is attached to the rear case of
each transfer case (Fig. 2). The ID tag provides the
transfer case model number, assembly number, serial
number, and low range ratio.The transfer case serial number also represents
the date of build.
SHIFT MECHANISM
Operating ranges are selected with a lever in the
floor mounted shifter assembly. The shift lever is con-
nected to the transfer case range lever by an adjust-
able cable. A straight line shift pattern is used.
Range positions are marked on the shifter bezel.
Fig. 1 NV242 Transfer Case
21 - 280 TRANSFER CASE - NV242WJ

(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 GEAR/LOW RANGE ASSEMBLY
(1) Remove front bearing retainer bolts.
(2) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 37). Position
screwdriver in slots cast into retainer.
(3) Remove input gear snap-ring (Fig. 38).
Fig. 34 Differential Removal
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 35 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 36 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 37 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
21 - 290 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(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)

(10) Install differential snap-ring (Fig. 74).
(11) Install intermediate clutch shaft (Fig. 75).
(12) Install clutch shaft thrust washer (Fig. 76).
(13) Install clutch shaft snap-ring (Fig. 77).(14) Inspect mode fork assembly (Fig. 78). Replace
pads and bushing if necessary. Replace fork tube if
bushings inside tube are worn or damaged. Also
check springs and slider bracket (Fig. 78). Replace
worn, damaged components.
Fig. 74 Installing Differential Snap-Ring
1 - DIFFERENTIAL SNAP-RING
Fig. 75 Installing Intermediate Clutch Shaft
1 - INTERMEDIATE CLUTCH SHAFT
Fig. 76 Installing Clutch Shaft Thrust Washer
1 - CLUTCH SHAFT THRUST RING
Fig. 77 Installing Clutch Shaft Snap-Ring
1 - SNAP-RING
2 - INTERMEDIATE CLUTCH SHAFT
21 - 302 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(15) Install mode sleeve in mode fork (Fig. 79).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(16) Install mode fork and mainshaft assembly in
case (Fig. 80). Rotate mainshaft slightly to engage
shaft with low range gears.
(17) Rotate mode fork pin into shift sector slot.Fig. 79 Installing Mode Fork And Sleeve
1 - MAINSHAFT
2 - MODE SLEEVE
3 - MODE FORK ASSEMBLY
Fig. 80 Assembled Mainshaft And Mode Fork
Installation
1 - MAINSHAFT ASSEMBLY
2 - MODE FORK
Fig. 78 Mode Fork Assembly Inspection
1 - SLIDER
2 - MODE FORK
3 - BUSHING/SPRING
4 - TUBE
5-PADS
WJTRANSFER CASE - NV242 21 - 303
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)