2003 JEEP GRAND CHEROKEE Transmission line

REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove transfer case drain plug and drain
transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped (Fig. 3).
(7) Disconnect front/rear propeller shafts at trans-
fer case. (Refer to 3 - DIFFERENTIAL & DRIV-
ELINE/PROPELLER SHAFT/PROPELLER SHAFT -
REMOVAL)
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 4) and
transfer case position sensor.
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission.(13) Pull transfer case and jack rearward to disen-
gage transfer case.
(14) Remove transfer case from under vehicle.
DISASSEMBLY
REAR RETAINER - NV242LD
(1) Remove output shaft boot. Spread band clamp
that secures boot on slinger with a suitable awl.
Then slide boot off shaft (Fig. 5).
Fig. 3 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
Fig. 4 Transfer Case Mounting
1 - NV242 TRANSFER CASE
Fig. 5 Output Boot - Typical
1 - SLINGER
2 - BOOT
3-AWL
4 - TRANSFER CASE
21 - 282 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

NV242HD REAR RETAINER
(1) Apply bead of MopartSealer, or LoctiteŸ
Ultra Gray, to mating surface of rear retainer. Sealer
bead should be a maximum of 3/16 in.
(2) Install rear retainer on rear case. Tighten
retainer bolts to 20-27 N´m (15-20 ft. lbs.) torque.
(3) Install new output shaft bearing snap-ring
(Fig. 91). Lift mainshaft slightly to seat snap-ring in
shaft groove, if necessary.
(4) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to mounting
surface of extension housing. Allow sealer to set-up
slightly before proceeding.(5) Install extension housing on rear retainer.
(6) Install extension housing bolts and tighten to
35-46 N´m (26-34 ft. lbs.).
COMPANION FLANGE
(1) Lubricate companion flange hub with transmis-
sion fluid and install flange on front shaft.
(2) Install new seal washer on front shaft.
(3) Install flange on front shaft and tighten nut to
122-176 N´m (90-130 ft. lbs.).
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. 4).
(6) Align and connect propeller shafts. (Refer to 3 -
DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - INSTALLATION)
(7) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(8) Install rear crossmember and skid plate, if
equipped. Tighten crossmember bolts to 41 N´m (30
ft. lbs.) torque.
(9) Remove transmission jack and support stand.
(10) Connect shift rod to transfer case range lever.
(11) Connect transfer case vent hose and transfer
case position sensor.
(12) Adjust transfer case shift cable.
(13) Lower vehicle and verify transfer case shift
operation.
Fig. 91 Install Output Bearing Snap-ring
1 - REAR RETAINER
2 - SNAP-RING
3 - REAR BEARING
WJTRANSFER CASE - NV242 21 - 307
TRANSFER CASE - NV242 (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)

CONDITION POSSIBLE CAUSE CORRECTION
NOISY INÐOR JUMPS OUT OF
4WD LOW RANGE1. Transfer case not completely
engaged in 4WD LOW (possibly
from shift to 4L while rolling)1. Stop vehicle, shift transfer case
to neutral, then shift back to 4WD
LOW
2. Shift linkage loose, binding, or is
misadjusted2. Tighten, lubricate, or repair
linkage as necessary. Adjust linkage
if necessary
3. Range fork cracked, inserts
worn, or fork is binding on shift rail3. Disassemble unit and repair as
necessary
4. Annulus gear or lockplate worn
or damaged4. Disassemble unit and repair as
necessary
LUBRICANT LEAKING FROM
OUTPUT SHAFT SEALS OR FROM
VENT1. Transfer case over filled 1. Drain to correct level
2. Vent closed or restricted 2. Clear or replace vent if necessary
3. Output shaft seals damaged or
installed correctly3. Replace seals. Be sure seal lip
faces interior of case when installed.
Also be sure yoke seal surfaces are
not scored or nicked. Remove
scores and nicks with fine
sandpaper or replace yoke(s) if
necessary.
REMOVAL
(1) Shift transfer case into NEUTRAL.
(2) Raise vehicle.
(3) Remove transfer case drain plug and drain
transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember and skid plate, if
equipped (Fig. 4).
(7) Disconnect front propeller shaft from transfer
case at companion flange. Remove rear propeller
shaft from vehicle. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - REMOVAL)
CAUTION: Do not allow propshafts to hang at
attached end. Damage to joint can result.
(8) Disconnect transfer case cable from range
lever.
(9) Disconnect transfer case vent hose (Fig. 5).
(10) Support transfer case with transmission jack.
(11) Secure transfer case to jack with chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Pull transfer case and jack rearward to disen-
gage transfer case (Fig. 5).
(14) Remove transfer case from under vehicle.
DISASSEMBLY
Position transfer case on shallow drain pan.
Remove drain plug and drain lubricant remaining in
case.
Fig. 4 Crossmember Removal
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
WJTRANSFER CASE - NV247 21 - 317
TRANSFER CASE - NV247 (Continued)

(6) Connect front propeller shaft and install rear
propeller shaft. (Refer to 3 - DIFFERENTIAL &
DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
(7) Fill transfer case with correct fluid. Check
transmission fluid level. Correct as necessary.
(8) Install rear crossmember (Fig. 71) and skid
plate, if equipped. Tighten crossmember bolts to 41
N´m (30 ft. lbs.) torque.
(9) Remove transmission jack and support stand.
(10) Verify transfer case is in NEUTRAL. Connect
shift cable to transfer case range lever.
(11) Lower vehicle and verify transfer case shift
operation.
(12) Adjust the transfer case shift cable, if neces-
sary.
SPECIFICATIONS
TRANSFER CASE - NV247
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Bolt, crossmember 41-47 30.2-34.7 -
Plug, Detent 16-24 11.8-17.7 -
Plugs, drain/fill 20-34 15-25 -
Bolts, front brg. retainer 16-24 11.8-17.7 -
Bolts, case half 27-34 19.9-25 -
Nut, companion flange 122-176 90-130 -
Bolts, rear extension 27-34 19.9-25 -
Lock-nut, shift 27-34 19.9-25 -
Nuts, T-case mount stud 33-41 24.3-30.2 -
Fig. 71 Crossmember Installation
1 - CROSSMEMBER
2 - REAR TRANSMISSION MOUNT
21 - 336 TRANSFER CASE - NV247WJ
TRANSFER CASE - NV247 (Continued)

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) Prior to installing the instrument panel into
the vehicle, loosen the three nuts that secure the
instrument panel intermediate bracket and the accel-
erator pedal assembly to the studs on the dash panel
(Fig. 8).
(2) With the aid of an assistant, load the instru-
ment panel assembly through the driver side front
door of the vehicle and hang it on the studs on the
dash panel near the windshield fence line (Fig. 1).
(3) Be certain that the molded plastic hook forma-
tions on the instrument panel structural duct are
inserted into and seated in the guide holes at each
cowl side inner panel.
(4) Loosely install the two screws that secure each
end of the instrument panel to the cowl side inner
panels.
(5) Install and tighten the two screws that secure
the passenger side instrument panel structural duct
to the heater and air conditioner housing (Fig. 13).
Tighten the screws to 11.8 N´m (105 in. lbs.).
(6) Install and tighten the one screw that secures
the instrument panel steering column support
bracket to the driver side end of the heater and air
conditioner housing (Fig. 7). Tighten the screw to
11.8 N´m (105 in. lbs.).
(7) Tighten the two screws that secure each end of
the instrument panel to the cowl side inner panels
(Fig. 10) and (Fig. 14). Tighten the screws to 11.8
N´m (105 in. lbs.).
(8) Install and tighten the one screw that secures
the instrument panel steering column support
bracket to the intermediate bracket on the driver
side dash panel (Fig. 8). Tighten the screw to 11.3
N´m (100 in. lbs.).
(9) Tighten the three nuts that secure the instru-
ment panel intermediate bracket and the accelerator
pedal assembly to the studs on the dash panel.
Tighten the nuts to 11.3 N´m (100 in. lbs.).(10) Install and tighten the four nuts that secure
the instrument panel to the studs on the dash panel
near the windshield fence line. Tighten the nuts to
11.8 N´m (105 in. lbs.).
(11) Install and tighten the nut that secures the
instrument panel steering column support bracket to
the stud on the driver side cowl plenum panel (Fig.
9). Tighten the nut to 28.2 N´m (250 in. lbs.).
(12) Reinstall the instrument panel to center floor
tunnel bracket onto the instrument panel and the
floor panel transmission tunnel. (Refer to 23 - BODY/
INSTRUMENT PANEL/IP CENTER FLOOR TUN-
NEL BRACKET - INSTALLATION).
(13) Reconnect the two instrument panel wire har-
ness connectors to the two heater and air conditioner
housing connectors located near the blower motor on
the passenger side end of the housing (Fig. 12).
(14) Reconnect the two halves of the radio antenna
coaxial cable connector near the right cowl side inner
panel under the end of the instrument panel.
(15) Reconnect the instrument panel wire harness
connector to the lower cavity of the inline connector
on the passenger side cowl side inner panel and
tighten the connector screw (Fig. 11). Tighten the
screw to 4 N´m (36 in. lbs.).
(16) Reinstall the lower right center bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP LOWER RIGHT CENTER BEZEL
- INSTALLATION).
(17) Reinstall the end cap onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL END CAP - INSTALLA-
TION).
(18) If the vehicle is equipped with the manual
heating and air conditioning system, reconnect the
vacuum harness connector located near the driver
side of the floor panel transmission tunnel behind
the driver side floor duct.
(19) Position the driver side floor duct to the
heater and air conditioner housing near the driver
side of the floor panel transmission tunnel (Fig. 7).
(20) Install and tighten the one screw that secures
the driver side floor duct to the heater and air con-
ditioner housing near the driver side of the floor
panel transmission tunnel. Tighten the screw to 2.2
N´m (20 in. lbs.).
(21) Route the instrument panel wire harness to
the floor panel transmission tunnel and engage the
retainers that secure the harness to the mounting
brackets on the tunnel (Fig. 6).
(22) Install the instrument panel wire harness
ground eyelets to the studs on the floor panel trans-
mission tunnel in front of and behind the airbag con-
trol module and secure the eyelets with nuts. Tighten
the nuts to 7.3 N´m (65 in. lbs.).
WJINSTRUMENT PANEL SYSTEM 23 - 43
INSTRUMENT PANEL SYSTEM (Continued)

(22) Remove the front bin from the floor console.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
REMOVAL).
(23) Reach through the front bin opening of the
floor console to access and remove the two screws
that secure the center floor tunnel bracket to the
instrument panel.
(24) Reach through the front bin opening of the
floor console to access and loosen the two nuts that
secure the center floor tunnel bracket to the studs on
the floor panel transmission tunnel.
(25) Slide the center floor tunnel bracket rearward
in the vehicle far enough to disengage the locating
hole in the lower flange of the top pad from the locat-
ing pin on the instrument panel structural duct (Fig.
25).
(26) Remove the instrument panel top pad from
the instrument panel structural duct.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.
If the top pad is being replaced with a new unit, be
certain to transfer or install the panel outlets and
the passenger side trim bezel to the new unit before
it is installed on the instrument panel structural
duct. (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/AIR OUTLETS - REMOVAL)
and (Refer to 23 - BODY/INSTRUMENT PANEL/IP
TRIM BEZEL - PASSENGER - REMOVAL).
(1) Position the instrument panel top pad over the
instrument panel structural duct and the studs on
the dash panel near the windshield fence line.
(2) Route the instrument panel wire harness take
out for the glove box lamp and switch unit to the
switch mounting hole in the upper glove box opening
reinforcement.
(3) Reach through the front bin opening of the
floor console to engage the locating hole in the lower
flange of the top pad with the locating pin on the
instrument panel structural duct (Fig. 25).
(4) Reach through the front bin opening of the
floor console to slide the center floor tunnel bracket
forward in the vehicle far enough to capture the
lower flange of the top pad between the bracket and
the structural duct.
(5) Reach through the front bin opening of the
floor console to install and tighten the two screws
that secure the center floor tunnel bracket to the
instrument panel. Tighten the screws to 11.8 N´m
(105 in. lbs.).
Fig. 25 Instrument Panel Top Pad Remove/Install
1 - STRUCTURAL DUCT
2 - LOCATING PIN
3 - INSTRUMENT PANEL TOP PAD
4 - LOWER FLANGE
5 - CENTER FLOOR TUNNEL BRACKET
23 - 54 INSTRUMENT PANEL SYSTEMWJ
INSTRUMENT PANEL TOP PAD (Continued)

(6) Reach through the front bin opening of the
floor console to access and tighten the two nuts that
secure the center floor tunnel bracket to the studs on
the floor panel transmission tunnel. Tighten the nuts
to 11.8 N´m (105 in. lbs.).
(7) Reinstall the front bin into the floor console.
(Refer to 23 - BODY/INTERIOR/FLOOR CONSOLE -
INSTALLATION).
(8) Install and tighten all of the screws that secure
the perimeter of the top pad to the instrument panel
structural duct. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(9) Install and tighten the four screws that secure
the heater-A/C control to the instrument panel struc-
tural duct. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(10) Install and tighten the four screws that secure
the radio to the instrument panel structural duct.
Tighten the screws to 2.2 N´m (20 in. lbs.).
(11) Reinstall the center lower bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP CENTER BEZEL - LOWER -
INSTALLATION).
(12) Reinstall the center upper bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP CENTER BEZEL - UPPER -
INSTALLATION).
(13) Install and tighten the two large screws on
the glove box opening upper reinforcement that
secure the top pad to the instrument panel structural
duct (Fig. 24). Tighten the screws to 11.8 N´m (105
in. lbs.).
(14) Install and tighten the two small screws on
the glove box opening upper reinforcement that
secure the panel outlets to the instrument panel
structural duct. Tighten the screws to 2.2 N´m (20 in.
lbs.).
(15) Reinstall the glove box lamp and switch into
the instrument panel. (Refer to 8 - ELECTRICAL/
LAMPS/LIGHTING - INTERIOR/GLOVE BOX
LAMP/SWITCH - INSTALLATION).
(16) Reinstall the lower right center bezel onto the
instrument panel. (Refer to 23 - BODY/INSTRU-
MENT PANEL/IP LOWER RIGHT CENTER BEZEL
- INSTALLATION).(17) Reinstall the end cap onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL END CAP - INSTALLA-
TION).
(18) Roll the glove box back up into the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
GLOVE BOX - STANDARD PROCEDURE - GLOVE
BOX ROLL DOWN).
(19) Reinstall the steering column opening cover
onto the instrument panel. (Refer to 23 - BODY/IN-
STRUMENT PANEL/STEERING COLUMN OPEN-
ING COVER - INSTALLATION).
(20) Reinstall the instrument cluster into the
instrument panel. (Refer to 8 - ELECTRICAL/IN-
STRUMENT CLUSTER - INSTALLATION).
(21) Reinstall the cluster bezel onto the instru-
ment panel. (Refer to 23 - BODY/INSTRUMENT
PANEL/CLUSTER BEZEL - INSTALLATION).
(22) If the vehicle is so equipped, position the
automatic headlamp light sensor/vehicle theft secu-
rity system indicator unit to the instrument panel
top pad just outboard of the driver side defroster out-
let. Install and tighten the two screws that secure
the sensor/indicator unit. Tighten the screws to 2.2
N´m (20 in. lbs.).
(23) Engage the retainer that secures each of the
two instrument panel wire harness speaker take outs
to the mounting hole in the instrument panel top
pad.
(24) Reinstall the speakers onto the instrument
panel top pad. (Refer to 8 - ELECTRICAL/AUDIO/
SPEAKER - INSTALLATION - INSTRUMENT
PANEL SPEAKER).
(25) Install and tighten the four nuts that secure
the instrument panel top pad to the studs on the
dash panel near the windshield fence line (Fig. 23).
Tighten the nuts to 11.8 N´m (105 in. lbs.).
(26) Reinstall the top cover onto the instrument
panel. (Refer to 23 - BODY/INSTRUMENT PANEL/
INSTRUMENT PANEL TOP COVER - INSTALLA-
TION).
(27) Reinstall the trim onto the right and left
A-pillars. (Refer to 23 - BODY/INTERIOR/A-PILLAR
TRIM - INSTALLATION).
(28) Reconnect the battery negative cable.
WJINSTRUMENT PANEL SYSTEM 23 - 55
INSTRUMENT PANEL TOP PAD (Continued)