2003 JEEP GRAND CHEROKEE Bolts

COMPANION FLANGE AND RANGE LEVER
(1) Remove transfer case position sensor (Fig. 19).
(2) Install two bolts (Fig. 20) partially into the pro-
pellor shaft companion flange, 180É from each other.
(3) Install the rectangular end of the Flange
Holder C-3281 over the bolts to hold the companion
flange stationary and remove the nut holding the
companion flange to the output shaft.
(4) Use Remover C-452 (Fig. 21) to remove the
companion flange.(5) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(6) Remove the bolt (Fig. 22) that attaches the
range lever to sector shaft. Then move sector to neu-
tral position and remove range lever from shaft.
NOTE: Be sure to note the orientation of the range
lever (lever up or down) so that it may be re-in-
stalled in the same direction.
Fig. 19 Remove Transfer Case Position Sensor
1 - TRANSFER CASE POSITION SENSOR
2 - TRANSFER CASE
Fig. 20 Hold Companion Flange - Typical
1 - HOLDER C-3281
2 - BOLTS
3 - COMPANION FLANGE
Fig. 21 Remove Companion Flange - Typical
1 - TRANSFER CASE
2 - COMPANION FLANGE
3 - REMOVER C-452
Fig. 22 Remove Shift Lever Bolt - Typical
1 - RANGE LEVER
2 - RANGE LEVER BOLT
3 - TRANSFER CASE
21 - 286 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(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 GEAR/LOW RANGE ASSEMBLY
(1) Remove front bearing retainer bolts.
(2) Remove front bearing retainer. Carefully pry
retainer loose with screwdriver (Fig. 37). Position
screwdriver in slots cast into retainer.
(3) Remove input gear snap-ring (Fig. 38).
Fig. 34 Differential Removal
1 - DIFFERENTIAL
2 - MAINSHAFT
Fig. 35 Low Range Fork And Hub Removal
1 - LOW RANGE FORK
2 - FORK HUB
Fig. 36 Remove the Shift Sector O-Ring
1 - TRANSFER CASE FRONT HOUSING
2 - SHIFT SECTOR O-RING
Fig. 37 Front Bearing Retainer Removal
1 - FRONT BEARING RETAINER
2 - RETAINER SLOT
21 - 290 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)

(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 retainer.
²rear retainer.
²oil pump.
²case halves.
DIFFERENTIAL
(1) Mark differential case halves for reference.
(2) Remove differential case bolts.
(3) Invert differential on workbench.
(4) Separate top case from bottom case. Use slots
in case halves to pry them apart (Fig. 43).
(5) Remove thrust washers and planet gears from
case pins (Fig. 44).
(6) Remove mainshaft and sprocket gears from
bottom case (Fig. 45). Note gear position for reference
before separating them.
CLEANING
Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and all
purpose cleaner. Use compressed air to remove sol-
vent residue from oil feed passages in the case
halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
Fig. 42 Inspecting Low Range Annulus Gear
1 - LOW RANGE ANNULUS GEAR
Fig. 43 Separating Differential Case Halves
1 - TOP CASE
2 - CASE BOLTS
3 - CASE BOLTS
4 - CASE SLOTS
5 - CASE BOLTS
Fig. 44 Planet Gears And Thrust Washer Removal
1 - MAINSHAFT GEAR
2 - THRUST WASHERS (12)
3 - PLANET GEARS (6)
21 - 292 TRANSFER CASE - NV242WJ
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)

FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Install front output shaft (Fig. 84).
(2) Install drive chain (Fig. 84). Engage chain with
front output shaft sprocket teeth.
(3) Install drive sprocket (Fig. 84). Engage drive
sprocket teeth with chain. Then engage sprocket
splines with mainshaft splines.
(4) Install drive sprocket snap-ring (Fig. 85).
OIL PUMP AND REAR CASE
(1) Insert oil pickup tube in oil pump and attach
oil screen and connector hose to pickup tube. Then
install assembled pump, tube and screen in rear case
(Fig. 86). Be sure screen is seated in case slot as
shown.
(2) Install magnet in front case pocket (Fig. 87).
(3) Apply 3 mm (1/8 in.) wide bead of Mopartgas-
ket maker or silicone adhesive sealer to seal surface
of front case.
(4) Align and install rear case on front case. Be
sure case locating dowels are in place and that main-
shaft splines are engaged in oil pump inner gear.
(5) Install and tighten front case-to-rear case bolts
to 41 N´m (30 ft. lbs.) torque.Be sure to install a
washer under each bolt used at case dowel
locations.
Fig. 84 Drive Chain And Sprocket Installation
1 - DRIVE SPROCKET
2 - DRIVE CHAIN
Fig. 85 Drive Sprocket Snap-Ring Installation
1 - DRIVE SPROCKET
2 - DRIVE SPROCKET SNAP-RING
Fig. 86 Oil Screen And Pickup Tube Installation
1 - OIL PUMP
2 - OIL SCREEN
3 - CONNECTOR
4 - PICKUP TUBE
WJTRANSFER CASE - NV242 21 - 305
TRANSFER CASE - NV242 (Continued)

REAR RETAINER - NV242LD
(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 rear bearing I.D. retaining ring and
spacer on output shaft.
(4) Apply liberal quantity of petroleum jelly to new
rear seal and to output shaft. Petroleum jelly is
needed to protect seal lips during installation.
(5) Slide seal onto Seal Protector 6992 (Fig. 88).
Slide seal protector and seal onto output shaft.(6) Slide Installer C-4076-B onto seal protector
with the recessed side of the tool toward the seal.
Drive seal into rear bearing retainer with Installer
C-4076-B and Handle MD-998323 (Fig. 89).
(7) Install rear slinger with Installer 8408.
(8) Install boot on output shaft slinger and crimp
retaining clamp with tool C-4975-A (Fig. 90).
Fig. 88 Output Shaft Seal and Protector
1 - OUTPUT SHAFT SEAL
2 - SPECIAL TOOL 6992
3 - TRANSFER CASE
Fig. 87 Installing Case Magnet
1 - MAGNET
Fig. 89 Rear Seal Installation
1 - SPECIAL TOOL 8691
2 - HANDLE
3 - TRANSFER CASE
Fig. 90 Slinger Boot Installation
1 - SPECIAL TOOL C-4975-A
2 - SLINGER
3 - BOOT
4 - CLAMP
21 - 306 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)

SPECIFICATIONS
TRANSFER CASE - NV242
TORQUE SPECIFICATIONS
DESCRIPTION N´m Ft. Lbs. In. Lbs.
Plug, Detent 16-24 11.8-17.7 -
Bolt, Diff. Case 17-27 12.5-19.9 -
Plug, Drain/Fill 20-34 15-25 -
Bolt, Front Brg. Retainer 16-27 11.8-19.9 -
Bolt, Case Half 35-46 25.8-33.9 -
Nut, Front Yoke 122-176 90-130 -
Screw, Oil Pump 1.2-1.8 - 12-15
Nut, Range Lever 27-34 19.9-25 -
Bolt, Rear Retainer 35-46 25.8-33.9 -
Nuts, Mounting 35 25.8 -
Bolts, U-Joint 19 14 -
SPECIAL TOOLS
TRANSFER CASE - NV242
Installer, Seal - C-4076-B
Handle, Universal - C-4171
Remover, Bearing - C-4210
Puller, Slinger - MD-998056-A
Installer - MD-998323
Installer, Bearing - 5064
21 - 308 TRANSFER CASE - NV242WJ
TRANSFER CASE - NV242 (Continued)