2002 JEEP GRAND CHEROKEE Gear

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Remove oil pickup tube from rear case (Fig.
17).
(2) Remove drive gear snap-ring (Fig. 18).
(3) Disengage drive gear (Fig. 18). Pry gear
upward and off mainshaft as shown.
(4) Remove front output shaft, drive chain and
drive gear as assembly (Fig. 18).
(5) Remove output shaft drive gear snap ring.
(6) Remove output shaft drive gear from output
shaft.
SHIFT FORKS AND MAINSHAFT
(1) Remove detent plug, O-ring, detent spring and
detent plunger (Fig. 19).
(2) Remove shift rail from shift fork and transfer
case housing.
(3) Rotate range shift fork until it disengages from
shift sector.
(4) Remove mainshaft and shift fork from input
gear pilot bearing.
NOTE: Loose needle bearings are used to support
the drive sprocket hub on the mainshaft. Do not lift
mainshaft by drive sprocket hub or needle bearings
will become dislodged.
(5) Wrap rag around mainshaft underneath drive
sprocket hub and remove drive sprocket hub from
mainshaft. Be sure to retrieve all the drive sprocket
hub needle bearings.
(6) Remove snap ring holding clutch sleeve onto
mainshaft.
Fig. 17 Oil Pickup Tube Removal
1 - OIL PICKUP TUBE
Fig. 18 Front Output Shaft, Drive Gear And Chain
Removal
1 - REAR HOUSING
2 - OUTPUT SHAFT AND SPROCKET
3 - MAINSHAFT SPROCKET
4 - SNAP-RING
5 - DRIVE CHAIN
Fig. 19 Detent Plug, Spring And Plunger Removal
1 - DETENT PLUG
2 - DETENT SPRING
3 - DETENT PLUNGER
4 - PLUG O-RING
WJTRANSFER CASE - NV247 21 - 321
TRANSFER CASE - NV247 (Continued)

(7) Remove range clutch sleeve, blockout spring,
locking clutch, and locking clutch spring from main-
shaft (Fig. 20).
(8) Remove shift sector. Rotate and tilt sector as
needed to remove it (Fig. 21).
(9) Remove shift sector bushing and O-ring (Fig.
22).
INPUT GEAR/LOW RANGE ASSEMBLY
(1) Turn front case on side so front bearing
retainer is accessible.
(2) Remove front bearing retainer bolts (Fig. 23).
(3) Remove front bearing retainer as follows:(a) Loosen retainer with flat blade screwdriver
to break sealer bead.To avoid damaging case
and retainer, position screwdriver blade only
in slots provided in retainer (Fig. 24).
(b) Then remove retainer from case and gear.
Fig. 20 Range Clutch Sleeve, Blockout Spring,
Locking Clutch and Spring
1 - LOCKING CLUTCH SPRING
2 - BLOCKOUT SPRING
3 - SNAP-RING
4 - RANGE CLUTCH SLEEVE
5 - LOCKING CLUTCH
6 - DRIVE SPROCKET HUB
Fig. 21 Shift Sector Removal
1 - SHIFT SECTOR
Fig. 22 Sector Bushing And O-Ring Removal
1 - SHIFT SECTOR BUSHING
2 - O-RING
Fig. 23 Front Bearing Retainer Bolt Removal
1 - FRONT BEARING RETAINER
21 - 322 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(4) Remove snap-ring that retains input gear shaft
in front bearing (Fig. 25).
(5) Remove input and low range gear assembly
(Fig. 26).
(6) Remove oil seals from following components:
²front bearing retainer.
²rear retainer.
²case halves.INPUT AND LOW RANGE GEAR
(1) Remove snap-ring that retains input gear in
low range gear (Fig. 27).
Fig. 24 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER NOTCH
3 - FLAT BLADE SCREWDRIVER
Fig. 25 Input Gear Snap-Ring Removal
1 - INPUT GEAR
2 - SNAP-RING
Fig. 26 Input And Low Range Gear Assembly
Removal
1 - INPUT AND LOW RANGE GEAR ASSEMBLY
Fig. 27 Input Gear Snap-Ring Removal
1 - INPUT GEAR SNAP-RING
WJTRANSFER CASE - NV247 21 - 323
TRANSFER CASE - NV247 (Continued)

(2) Remove retainer (Fig. 28).
(3) Remove front tabbed thrust washer (Fig. 29).
(4) Remove input gear (Fig. 30).
(5) Remove rear tabbed thrust washer from low
range gear (Fig. 31).
CLEANING
Clean the transfer case components with parts
cleaning solvent. Flush the oil passages in the cases
and drivetrain components with solvent. This will
help remove dirt and particles from these passages.
Dry the transfer case components with compressed
air or allow them to air dry on clean shop towels.
Apply compressed air through all oil passages in
the cases and gear components to clear them of any
residue.
INSPECTION
MAINSHAFT
Examine the mainshaft components carefully for
evidence of wear or damage.
Replace the thrust washers if worn or damaged.
Replace the mainshaft and sprocket gears if the
teeth or gear bores are worn or damaged.
Replace the mainshaft bearings if worn, flat spot-
ted, brinelled, or damaged in any way.
Replace the mainshaft if it is bent, exhibits wear or
damage to the bearing surfaces, splines or gear teeth.
Fig. 28 Input Gear Retainer
1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER
Fig. 29 Front Tabbed Thrust Washer
1 - FRONT TABBED THRUST WASHER
Fig. 30 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
Fig. 31 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
21 - 324 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

INPUT AND LOW RANGE GEARS
Inspect the low range gear pinions and pinion pins.
Replace the low range gear if any of the pins or pin-
ions are worn or damaged.
Inspect the thrust washers, retainer, and snap-
ring. Replace the snap-ring if bent, or distorted.
Replace the thrust washers and retainer if worn,
cracked or damaged in any way.
Examine the input gear carefully. Be sure the gear
teeth and bearing surfaces are in good condition.
Replace the gear if wear or damage is evident.
Check the input gear pilot bearing. Rotate the
bearing and check for roughness or noise. Also check
bearing position in the bore. The bearing should be
recessed approximately 2.5 mm (0.100 in.) below the
top edge of the bore. The bearing should not be
seated at the bottom of the bore. Replace the bearing
if worn, or roughness is evident. Replace both the
gear and bearing if the bearing is a loose fit in the
bore.
GEAR CASE AND RETAINERS
Examine both case halves and retainers carefully.
Replace any retainer or case half if wear, cracks, or
other damage is evident.
Check condition of the low range annulus gear and
the shift rail bushing in the front case (Fig. 32). The
low range annulus gear is not a serviceable part.
Replace the gear and case as an assembly if the gear
is loose, worn, or damaged. The shift rail bushing is
a serviceable part and can be replaced if necessary.
Check the bushing in the rear retainer. Replace the
bushing if worn or scored.
Examine the sealing surfaces of both case halves
and retainers. Small burrs, or scratches on these sur-
faces can be reduced with crocus cloth or a fine tooth
file.
Examine condition of the shift rail bushing in the
front case. If the bushing is worn or damaged, it can
be removed with a blind hole type puller. A replace-
ment bushing can be installed with a suitable size
driver. Recess the bushing slightly below the edge of
the bore but do not seat it all the into the case.
GEARTRAIN
Inspect the mainshaft splines, gear teeth and bear-
ing surfaces carefully for evidence of wear, or dam-
age. Replace the shaft if necessary. do not attempt to
salvage it if damaged.
The shift rail and range fork are an assembly.
Replace both parts if either is damaged. However, the
nylon pads in the fork can be replaced if worn, or
cracked.
Inspect the transfer case snap-rings closely. Do not
attempt to salvage a distorted snap-ring by straight-ening or reshaping it. Replace any snap-ring that is
distorted, or worn.
Inspect the low range gear, input gear and the gear
thrust washers retainer, and snap-ring. The low
range gear is serviced as an assembly only. Replace
the gear if the case or pinions are damaged.
During inspection, also make sure the seal surface
of the input gear is in good condition. Minor nicks on
this surface can be reduced with crocus cloth. How-
ever, replace the gear if the seal surface is severely
scored or worn.
OIL PUMP AND PROGRESSIVE COUPLING
The oil pump and progressive coupling are not ser-
viceable components. Replace the coupling as an
assembly if it is damaged. Replace the oil pump as
an assembly if the gear teeth are worn, or if the
pump has become damaged.
BEARINGS AND SEALS
The transfer case seals should be replaced during
overhaul. Use new seals in the input gear bearing
retainer, front case and rear retainer. Also replace
the yoke seal washer and the detent plug O-ring.
Check condition of each transfer case bearing.
Replace any bearing exhibiting signs of roughness,
wear, or damage.
Fig. 32 Low Range Annulus Gear Location
1 - LOW RANGE ANNULUS GEAR
2 - SHIFT RAIL BUSHING
WJTRANSFER CASE - NV247 21 - 325
TRANSFER CASE - NV247 (Continued)

(9) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing from inside the annulus
gear opening in the case. (Fig. 40).
(10) Install locating ring on new bearing.
(11) Position case so forward end is facing upward.
(12) Using Remover C-4210 and Handle C-4171,
drive input shaft bearing into case. The bearing
locating ring must be fully seated against case sur-
face (Fig. 41).
(13) Remove input gear pilot bearing by inserting
a suitably sized drift into the splined end of the inputgear and driving the bearing out with the drift and a
hammer (Fig. 42).
(14) Install new pilot bearing with Installer 8128
and Handle C-4171 (Fig. 43).
Fig. 40 Input Shaft Bearing Removal
1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210
Fig. 41 Seating Input Shaft Bearing
1 - SNAP-RING
2 - INPUT SHAFT BEARING
Fig. 42 Remove Input Gear Pilot Bearing
1 - DRIFT
2 - INPUT GEAR
Fig. 43 Install Input Gear Pilot Bearing
1 - HANDLE C-4171
2 - INSTALLER 8128
3 - INPUT GEAR
21 - 328 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(15) Remove front bearing retainer seal with suit-
able pry tool.
(16) Install new front bearing retainer with
Installer 7884 (Fig. 44).
INPUT AND LOW RANGE GEAR
(1) Lubricate gears and thrust washers (Fig. 45)
with transfer case lubricant.
(2) Install first thrust washer in low range gear
(Fig. 45). Be sure washer tabs are properly aligned in
gear notches.
(3) Install input gear in low range gear. Be sure
input gear is fully seated.
(4) Install remaining thrust washer in low range
gear and on top of input gear. Be sure washer tabs
are properly aligned in gear notches.
(5) Install retainer on input gear and install snap-
ring.
(6) Align and install low range/input gear assem-
bly in front case (Fig. 46). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
Fig. 44 Install Front Bearing Retainer Seal
1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884
Fig. 45 Input/Low Range Gear Components
1 - SNAP-RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS
Fig. 46 Input/Low Range Gear Installation
1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR
WJTRANSFER CASE - NV247 21 - 329
TRANSFER CASE - NV247 (Continued)

(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)