2002 JEEP GRAND CHEROKEE Rear main seal

REAR RETAINER AND OIL PUMP
(1) Remove rear retainer bolts (Fig. 6).
(2) Remove rear bearing locating ring access plug
(Fig. 7).(3) Loosen rear retainer with pry tool to break
sealer bead. Pry only against retainer boss as shown
(Fig. 8).
(4) Remove rear retainer as follows:
(a) Spread rear bearing locating ring with snap
ring pliers (Fig. 9).
(b) Then slide retainer off mainshaft and rear
bearing (Fig. 10).
Fig. 5 Transfer Case Mounting
1 - NV247 TRANSFER CASE
Fig. 6 Rear Retainer Bolt Removal
1 - REAR RETAINER
Fig. 7 Remove Rubber Access Plug
1 - PLUG
Fig. 8 Loosening Rear Retainer
1 - RETAINER BOSS
2-PRYTOOL
3 - SEALER BEAD
4 - REAR RETAINER
21 - 318 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

REAR CASE
(1) Support transfer case so rear case is facing
upward.
(2) Remove bolts holding front case to rear case.
The case alignment bolt require flat washers (Fig.
13).
(3) Loosen rear case with flat blade screwdriver to
break sealer bead. Insert screwdriver blade only into
notches provided at each end of case (Fig. 14).
(4) Remove rear case (Fig. 15).
PROGRESSIVE COUPLING
(1) Remove oil pump locating snap-ring and pro-
gressive coupling thrust washer from the mainshaft
(Fig. 16).
(2) Remove progressive coupling from mainshaft
(Fig. 16).
Fig. 13 Rear Case Alignment Bolt Locations
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
Fig. 14 Loosening Rear Case
1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE
Fig. 15 Rear Case Removal
1 - REAR HOUSING
2 - MAINSHAFT
3 - TRANSFER CASE
Fig. 16 Progressive Coupling Removal
1 - SNAP-RING
2 - PROGRESSIVE COUPLING
21 - 320 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)

(12) Clean sealing flanges of front case and rear
case with a wax and grease remover.
(13) Apply 3 mm (1/8 in.) wide bead of Mopart
gasket maker or silicone adhesive sealer to mounting
flange of front case. Work sealer bead around bolt
holes as shown (Fig. 58).
(14) Align and install rear case on front case (Fig.
59).(15) Verify that oil pickup tube is still seated in
case notch and tube end is pointed toward mainshaft
(Fig. 60).
(16) Install case attaching bolts. Alignment bolts
at each end of case are only ones requiring washers
(Fig. 61).
(17) Tighten case bolts to 27-34 N´m (20-25 ft. lbs.)
torque.
Fig. 58 Applying Sealer To Front Case Flange
1 - FRONT CASE FLANGE
2 - SEALER BEAD
Fig. 59 Rear Case Installation
1 - REAR CASE
2 - FRONT CASE
Fig. 60 Checking Position Of Oil Pickup Tube
1 - TUBE O-RING
2 - CORRECT PICKUP TUBE POSITION
Fig. 61 Alignment Bolt
1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)
WJTRANSFER CASE - NV247 21 - 333
TRANSFER CASE - NV247 (Continued)

COMPANION FLANGE AND RANGE LEVER
(1) Install range lever, washer and locknut on sec-
tor shaft (Fig. 62). Tighten locknut to 27-34 N´m
(20-25 ft. lbs.) torque.
(2) Install new seal washer on front output shaft
(Fig. 63).
(3) Lubricate flange hub with transfer case lubri-
cant and install flange on front shaft.
(4) Install new seal washer on front shaft.
(5) Install companion flange and new nut on front
output shaft.
(6) Tighten flange nut to 122-176 N´m (90-130 ft.
lbs.) torque. Use Tool C-3281, or similar tool to hold
flange while tightening yoke nut.
REAR RETAINER AND OIL PUMP
(1) Install new O-ring on flanged end of oil pickup
tube.
(2) Install oil pump (Fig. 64).
(3) Insert oil pickup tube in pump (Fig. 65).(4) Install rear bearing on mainshaft (Fig. 65).
Locating ring groove in bearing goes toward end of
mainshaft.
(5) Install rear bearing retaining snap-ring (Fig.
66).
(6) Install rear bearing locating ring in rear
retainer, if ring was removed during overhaul.
Fig. 62 Range Lever Installation - Typical
1 - RANGE LEVER
2 - WASHER
3 - LOCKNUT
Fig. 63 Flange Seal Washer Installation
1 - YOKE SEAL WASHER
Fig. 64 Installing Oil Pump
1 - OIL PUMP
2 - TUBE O-RING
3 - OIL PICKUP TUBE
Fig. 65 Rear Bearing Installation
1 - REAR BEARING
Fig. 66 Rear Bearing Snap-Ring Installation
1 - REAR BEARING
2 - SNAP-RING PLIERS
3 - SNAP-RING
21 - 334 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

(7) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to mounting
surface of rear retainer. Allow sealer to set-up
slightly before proceeding.
(8) Slide rear retainer onto mainshaft (Fig. 67).
(9) Spread rear bearing locating ring and slide
rear retainer into place on rear case (Fig. 68).
(10) Install and tighten rear retainer bolts to 27-34
N´m (20-25 ft. lbs.).
(11) Install rubber access plug (Fig. 69).
FINAL ASSEMBLY
(1) Install drain plug. Tighten plug to 41-54 N´m
(30-40 ft. lbs.) torque.(2) Level transfer case and fill it with Mopart
Transfer Case Lubricant. Correct fill level is to bot-
tom edge of fill plug hole.
(3) Install and tighten fill plug to 41-54 N´m
(30-40 ft. lbs.) torque.
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N´m (26 ft. lbs.) torque (Fig. 70).Fig. 67 Rear Retainer Installation
1 - REAR CASE
2 - REAR RETAINER
Fig. 68 Engaging Rear Bearing Locating Ring
1 - REAR RETAINER
2 - PARALLEL JAW SNAP-RING PLIERS
Fig. 69 Installing Rubber Access Plug
1 - PLUG
Fig. 70 Install Transfer Case
1 - NV247 TRANSFER CASE
WJTRANSFER CASE - NV247 21 - 335
TRANSFER CASE - NV247 (Continued)

BODY
TABLE OF CONTENTS
page page
BODY
DIAGNOSIS AND TESTING
WATER LEAKS........................1
WIND NOISE..........................2
STANDARD PROCEDURE
STANDARD PROCEDURE - BODY
LUBRICATION.........................2
STANDARD PROCEDURE - DRILLING AND
WELDING............................3
SPECIFICATIONS
BODY LUBRICANTS....................3
SPECIFICATIONS - TORQUE.............4
SPECIAL TOOLS
BODY...............................4DECKLID/HATCH/LIFTGATE/TAILGATE........5
DOOR - FRONT.........................11
DOORS - REAR.........................19
EXTERIOR.............................25
HOOD.................................33
INSTRUMENT PANEL SYSTEM.............36
INTERIOR..............................69
PAINT.................................81
SEATS................................83
STATIONARY GLASS.....................93
SUNROOF.............................96
WEATHERSTRIP/SEALS..................105
BODY STRUCTURE.....................112
BODY
DIAGNOSIS AND TESTING
WATER LEAKS
Water leaks can be caused by poor sealing,
improper body component alignment, body seam
porosity, missing plugs, or blocked drain holes. Cen-
trifugal and gravitational force can cause water to
drip from a location away from the actual leak point,
making leak detection difficult. All body sealing
points should be water tight in normal wet-driving
conditions. Water flowing downward from the front of
the vehicle should not enter the passenger or luggage
compartment. Moving sealing surfaces will not
always seal water tight under all conditions. At
times, side glass or door seals will allow water to
enter the passenger compartment during high pres-
sure washing or hard driving rain (severe) condi-
tions. Overcompensating on door or glass
adjustments to stop a water leak that occurs under
severe conditions can cause premature seal wear and
excessive closing or latching effort. After completing
a repair, water test vehicle to verify leak has stopped
before returning vehicle to use.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Verify that floor and body plugs are in place, body
drains are clear, and body components are properly
aligned and sealed. If component alignment or seal-
ing is necessary, refer to the appropriate section of
this group for proper procedures.
WATER LEAK TESTS
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS
OR TOOLS IN WATER TEST AREA. PERSONAL
INJURY CAN RESULT.
When the conditions causing a water leak have
been determined, simulate the conditions as closely
as possible.
²If a leak occurs with the vehicle parked in a
steady light rain, flood the leak area with an open-
ended garden hose.
²If a leak occurs while driving at highway speeds
in a steady rain, test the leak area with a reasonable
velocity stream or fan spray of water. Direct the
spray in a direction comparable to actual conditions.
²If a leak occurs when the vehicle is parked on an
incline, hoist the end or side of the vehicle to simu-
late this condition. This method can be used when
the leak occurs when the vehicle accelerates, stops or
turns. If the leak occurs on acceleration, hoist the
front of the vehicle. If the leak occurs when braking,
hoist the back of the vehicle. If the leak occurs on left
turns, hoist the left side of the vehicle. If the leak
occurs on right turns, hoist the right side of the vehi-
cle. For hoisting recommendations refer to Group 0,
Lubrication and Maintenance, General Information
section.
WATER LEAK DETECTION
To detect a water leak point-of-entry, do a water
test and watch for water tracks or droplets forming
on the inside of the vehicle. If necessary, remove inte-
rior trim covers or panels to gain visual access to the
WJBODY 23 - 1

INSTRUMENT PANEL
STUCTURAL DUCT
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS,
DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPT-
ING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN-
UTES FOR THE AIRBAG SYSTEM CAPACITOR TO DIS-
CHARGE BEFORE PERFORMING FURTHER
DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE
WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO
TAKE THE PROPER PRECAUTIONS COULD RESULT
IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI-
BLE PERSONAL INJURY.
(1)Disconnect and isolate the battery negative cable.
(2) Remove the instrument panel from the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL -
REMOVAL).
(3) Place the instrument panel on a suitable work
surface. Be certain to take the proper precautions to
protect the instrument panel from any possible cos-
metic damage.
(4)
Remove all of the individual components that
remain secured to the instrument panel structural duct
as described elsewhere in this service information.
INSTALLATION
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Reinstall all of the individual components that
were removed from the instrument panel structural
duct as described elsewhere in this service informa-
tion.
(2) Reinstall the instrument panel into the vehicle.
(Refer to 23 - BODY/INSTRUMENT PANEL -
INSTALLATION).
(3) Reconnect the battery negative cable.
INSTRUMENT PANEL TOP
COVER
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.
(1) Disconnect and isolate the battery negative
cable.
(2) Using a trim stick or another suitable wide
flat-bladed tool, gently pry the rear edge (farthest
from the windshield) of the top cover up and away
from the instrument panel far enough to disengage
the four snap clip retainers from their receptacles in
the instrument panel top pad (Fig. 22).
(3) Remove the top cover from the top of the
instrument panel.
Fig. 22 Instrument Panel Top Cover Remove/Install
1 - ULTRA LIGHT SENSOR PLUG
2 - SEAL
3 - INSTRUMENT PANEL TOP COVER
WJINSTRUMENT PANEL SYSTEM 23 - 51