2003 JEEP GRAND CHEROKEE hub bearing

(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)

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 damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (Fig. 46). Minor nicks
can be dressed off with an oilstone but replace the
gear if any teeth are broken, cracked, or chipped. The
bearing surface on the gear can be smoothed with
300-400 grit emery cloth if necessary.
Examine the carrier body and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
Fig. 46 Input Gear And Carrier Components
1 - PLANETARY CARRIER 4 - CARRIER LOCK RING
2 - REAR THRUST WASHER 5 - CARRIER LOCK RETAINING RING
3 - FRONT THRUST WASHER 6 - INPUT GEAR
Fig. 45 Mainshaft And Sprocket Gear Removal
1 - MAINSHAFT GEAR
2 - SPROCKET GEAR
3 - BOTTOM CASE
WJTRANSFER CASE - NV242 21 - 293
TRANSFER CASE - NV242 (Continued)

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 pads. The mode fork
pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.
Check both of the sleeves for wear or damage,
especially on the interior teeth. Replace the sleeves if
wear or damage is evident.
REAR RETAINER/BEARING/ SEAL/SLINGER/BOOT
Inspect the retainer components (Fig. 48). Replace
the bearing if rough or noisy. Check the retainer for
cracks or wear in the bearing bore. Clean the
retainer sealing surfaces with a scraper and 3M all
purpose cleaner. This will ensure proper adhesion of
the sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Replace any part if distorted, bent, or broken. Also
replace the boot if cut or torn. Replace the boot band
clamps, do not reuse them.
Fig. 48 Rear Retainer - Typical
1 - REAR RETAINER 5 - BAND CLAMPS
2 - REAR BEARING I.D. MAINSHAFT RETAINING RING 6 - REAR SLINGER
3 - REAR SEAL 7 - REAR BEARING O.D. RETAINING RING
4 - BOOT 8 - REAR BEARING
Fig. 47 Shift Fork And Wear Pad Locations
1 - MODE FORK
2 - RANGE FORK
3 - WEAR PADS (SERVICEABLE)
4 - WEAR PADS (SERVICEABLE)
21 - 294 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)

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)

(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)

(6) Install range shift fork to range clutch sleeve.
Install mainshaft/range shift fork assembly into
transfer case and input planetary assembly. Rotate
fork until it engages with slot in shift sector.
(7) Install shift rail to shift range fork and trans-
fer case housing.
(8) Rotate shift sector to NEUTRAL position.
(9) Install new O-ring on detent plug (Fig. 52).
(10) Lubricate detent plunger with transfer case
lubricant or light coat of petroleum jelly.
(11) Install detent plunger, spring and plug (Fig.
52).
(12)
Verify that plunger is properly engaged in sector.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
(1) Lubricate front output shaft-sprocket assembly,
drive chain and drive sprocket with transfer case
lubricant.
(2) Assemble drive chain, drive sprocket and front
output shaft (Fig. 53).
(3) Start drive sprocket on mainshaft.
(4) Guide front shaft into bearing and drive
sprocket onto mainshaft drive gear (Fig. 53).
(5) Install drive sprocket snap-ring (Fig. 54).
Fig. 51 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. 52 Shift Detent Components
1 - DETENT PLUG
2 - DETENT SPRING
3 - DETENT PLUNGER
4 - PLUG O-RING
Fig. 53 Installing Drive Chain, Front Output Shaft
And Drive Sprocket
1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE GEAR
WJTRANSFER CASE - NV247 21 - 331
TRANSFER CASE - NV247 (Continued)