2002 JEEP GRAND CHEROKEE 242 transfer case

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) Install new front output shaft front bearing
with Tool Handle C-4171 and Installer 8033-A with
the tapered cone upward (Fig. 52).(3) Install front bearing snap-ring (Fig. 51).
(4) Remove front output shaft seal using an appro-
priate pry tool (Fig. 53) or slide-hammer mounted
screw.
(5) Install new front output shaft oil seal with
Installer 6952-A (Fig. 54).
Fig. 51 Front Output Shaft Front Bearing Snap-Ring
Removal
1 - FRONT BEARING SNAP-RING
Fig. 52 Front Output Shaft Front Bearing Installation
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 8033-A
Fig. 53 Remove Front Output Shaft Seal
1 - OUTPUT SHAFT SEAL
2 - PRYBAR
Fig. 54 Install Front Output Shaft Seal
1 - INSTALLER 6952-A
2 - TRANSFER CASE
21 - 296 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(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 Remover C-4210. Install bearing far
enough to seat snap-ring against case (Fig. 56).
(9) Remove the input gear pilot bearing by insert-
ing a suitably sized drift into the splined end of the
input gear and driving the bearing out with the drift
and a hammer (Fig. 57).(10) Install new pilot bearing with Installer 8128
and Handle C-4171 (Fig. 58).
Fig. 55 Input Gear Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 56 Seating Input Gear Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 57 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 58 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
WJTRANSFER CASE - NV242 21 - 297
TRANSFER CASE - NV242 (Continued)

(11) Install new seal in front bearing retainer with
Installer 7884 (Fig. 59).
(12) Remove output shaft rear bearing with the
screw and jaws from Remover L-4454 and Cup 8148
(Fig. 60).(13) Install new bearing with Tool Handle C-4171
and Installer 5066 (Fig. 61). Lubricate bearing after
installation.
(14) Install new seal in oil pump feed housing with
Special Tool 7888 (Fig. 62).
Fig. 59 Front Bearing Retainer Seal Installation
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 60 Remove Front Output Shaft Rear Bearing
1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148
Fig. 61 Install Front Output Shaft Rear Bearing
1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066
Fig. 62 Oil Pump Seal Installation
1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING
21 - 298 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(15) Install new pickup tube O-ring in oil pump
(Fig. 63).
(16) Remove rear retainer bearing with Installer
8128 and Handle C-4171, NV242HD only.
(17) Install rear bearing in retainer with Handle
C-4171 and Installer 5064 (Fig. 64), NV242HD only.
DIFFERENTIAL
(1) Lubricate differential components with auto-
matic transmission fluid.
(2) Install sprocket gear in differential bottom case
(Fig. 65).(3) Install differential planet gears and new thrust
washers (Fig. 66).Be sure thrust washers are
installed at top and bottom of each planet gear.
(4) Install differential mainshaft gear (Fig. 66).
Fig. 63 Pickup Tube O-Ring Installation
1 - PICKUP TUBE O-RING
Fig. 64 Installing Rear Bearing In Retainer
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
3 - REAR RETAINER
Fig. 65 Installing Differential Sprocket Gear
1 - SPROCKET GEAR
2 - BOTTOM CASE
Fig. 66 Installing Mainshaft And Planet Gears
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
WJTRANSFER CASE - NV242 21 - 299
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)

(5)Position low range fork and sleeve in case. Be
sure low range fork pin is engaged in shift sector slot.
(6) Install first mainshaft bearing spacer on main-
shaft (Fig. 72).
(7) Install bearing rollers on mainshaft (Fig. 72).
Coat bearing rollers with generous quantity of petro-
leum jelly to hold them in place.
(8) Install remaining bearing spacer on mainshaft
(Fig. 72). Do not displace any bearings while install-
ing spacer.(9) Install differential (Fig. 73). Do not displace
mainshaft bearings when installing differential.
Fig. 70 Input Gear Snap-Ring Installation
1 - INPUT GEAR
2 - SNAP-RING
Fig. 71 Installing Front Bearing Retainer
1 - FRONT BEARING RETAINER
Fig. 72 Installing Mainshaft Bearing Rollers and
Spacers
1 - MAINSHAFT BEARING ROLLERS
2 - BEARING SPACERS
Fig. 73 Differential Installation
1 - DIFFERENTIAL
2 - MAINSHAFT
WJTRANSFER CASE - NV242 21 - 301
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)