2003 JEEP GRAND CHEROKEE 242 transfer case

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Page 1807 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (2) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole.
(3) Remove range fork lockpin with size number
one easy-out tool

Page 1808 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (7) Remove intermediate clutch shaft snap-ring
(Fig. 30).
(8) Remove clutch shaft thrust ring (Fig. 31).
(9) Remove intermediate clutch shaft (Fig. 32).
(10) Remove differential snap-ring (Fig. 33).
(

Page 1809 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (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

Page 1810 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (4) Remove input/low range gear assembly from
bearing with Tool Handle C-4171 and Tool 7829A
(Fig. 39).
(5) Remove low range gear snap-ring (Fig. 40).
(6) Remove input gear retainer, thrust washers
an

Page 1811 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual (7) Inspect low range annulus gear (Fig. 42).Gear
is not a serviceable component. If damaged,
replace gear and front case as assembly.
(8) Remove oil seals from following components:
²front bearing r

Page 1812 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual INSPECTION
MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part that is

Page 1813 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 47). Minor nicks on the shift rail can
be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear

Page 1814 of 2199

JEEP GRAND CHEROKEE 2003 WJ / 2.G Workshop Manual REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 49). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut an