Jeep Cherokee (XJ): Disassembly and assembly

NV231 TRANSFER CASE

DISASSEMBLY

Position transfer case on shallow drain pan.

Remove drain plug and drain lubricant remaining in case.

REAR RETAINER AND OIL PUMP REMOVAL

(1) Remove the speedometer adapter.

(2) Spread band clamp which holds output shaft boot to slinger with a suitable awl, or equivalent.

(3) Remove output shaft boot from slinger and output shaft.

(4) Using Puller MD-998056-A, remove rear slinger (Fig. 9).

(5) Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer (Fig. 10).

(6) Remove the rear output bearing I. D. retaining ring (Fig. 11).

(7) Remove the bolts holding the rear retainer to the rear case half.

(8) Tap rear retainer with rawhide or rubber mallet to loosen sealer bead.

Fig. 9 Rear Slinger Removal

1 - TRANSFER CASE
2 - SPECIAL TOOL MD998056-A
3 - SLINGER

Fig. 10 Rear Retainer Seal

1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL

(9) Remove rear retainer from rear case half (Fig.

12).

(10) Remove snap-ring holding oil pump in position on output shaft.

(11) Disengage oil pickup tube from oil pump and remove oil pump assembly. Remove oil pump by tilting the edge of the oil pump from under the edge of the rear case half and sliding the pump (Fig. 13).

(12) Remove pick-up tube o-ring from oil pump (Fig. 14), if necessary. Do not disassemble the oil pump, it is not serviceable.

Fig. 11 Output Shaft Rear Bearing Retaining Ring

1 - REAR RETAINER
2 - OUTPUT SHAFT SEAL

Fig. 12 Rear Retainer Removal

1 - MAINSHAFT
2 - REAR RETAINER

Fig. 13 Oil Pump Removal

1 - OIL PUMP]

Fig. 14 Pick-up Tube O-ring Location

1 - OIL PUMP
2 - O-RING

YOKE AND RANGE LEVER REMOVAL

(1) Remove transfer case indicator switch.

(2) Remove front yoke nut as follows: (a) Move range lever to 4L position.

(b) Then remove nut with socket and impact wrench (Fig. 15).

(3) Remove yoke. If yoke is difficult to remove by hand, remove it with bearing splitter, or with standard two jaw puller (Fig. 16). Be sure puller tool is positioned on yoke and not on slinger as slinger will be damaged.

Fig. 15 Yoke Nut Removal

1 - IMPACT WRENCH
2 - SOCKET
3 - YOKE

Fig. 16 Yoke Removal

1 - PULLER TOOL
2 - YOKE

(4) Remove seal washer from front output shaft.

Discard washer as it should not be reused.

(5) Remove nut and washer that attach range lever to sector shaft. Then move sector to neutral position and remove range lever from shaft (Fig. 17).

Fig. 17 Range Lever Removal

1 - RANGE LEVER
2 - SECTOR SHAFT

FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL

(1) Support transfer case so rear case is facing upward.

(2) Remove bolts holding front case to rear case.

The case alignment bolts require flat washers (Fig.

18).

(3) Loosen rear case with flat blade screwdriver to break sealer bead. Insert pry tool blade only into notches provided at each end of case (Fig. 19).

(4) Remove rear case from front case.

Fig. 18 Rear Case Alignment Bolt Locations

1 - DOWEL BOLT AND WASHER (2)
2 - CASE BOLT (5)
3 - SPLINE HEAD BOLT (1)

Fig. 19 Loosening Rear Case

1 - REAR CASE
2 - PRY TOOL (IN CASE SLOT)
3 - FRONT CASE

(5) Remove oil pickup tube from rear case (Fig.

20).

(6) Remove mode fork spring (Fig. 21).

(7) Pull front output shaft upward and out of front output shaft bearing (Fig. 22).

(8) Remove front output shaft and chain.

Fig. 20 Oil Pickup Tube Removal

1 - CONNECTING HOSE
2 - PICKUP SCREEN
3 - PICKUP TUBE

Fig. 21 Mode Fork Spring Removal

1 - MODE SPRING

Fig. 22 Remove Front Output Shaft And Chain

1 - DRIVE CHAIN
2 - FRONT OUTPUT SHAFT
3 - SHAFT FRONT BEARING

SHIFT FORKS AND MAINSHAFT REMOVAL

(1) Remove detent plug, O-ring, detent spring and detent plunger (Fig. 23).

(2) Remove mainshaft from mode sleeve and input gear pilot bearing.

Fig. 23 Detent Plug, Spring And Plunger Removal

1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)

(3) Remove mode fork and sleeve as an assembly (Fig. 24). Note position of sleeve for assembly reference.

The short side of the sleeve faces upward.

(4) Remove range fork and hub as an assembly (Fig. 25). Note fork position for installation reference.

(5) Remove shift sector from front case (Fig. 26).

(6) Remove shift sector bushing and O-ring (Fig.

27).

Fig. 24 Mode Fork And Sleeve Removal

1 - MODE SLEEVE
2 - MODE FORK AND RAIL

Fig. 25 Range Fork And Hub Removal

1 - RANGE HUB
2 - RANGE FORK

Fig. 26 Shift Sector Removal

1 - SHIFT SECTOR

Fig. 27 Sector Bushing And O-Ring Re

1 - SEAL RETAINER
2 - SECTOR SHAFT BORE
3 - O-RING SEAL

MAINSHAFT DISASSEMBLY

(1) Remove mode hub retaining ring with heavy duty snap-ring pliers (Fig. 28).

(2) Slide mode hub off mainshaft (Fig. 29).

(3) Slide drive sprocket off mainshaft (Fig. 30).

Fig. 28 Mode Hub Retaining Ring Removal

1 - MODE HUB
2 - SNAP RING PLIERS (HEAVY DUTY)
3 - MODE HUB RETAINING RING

Fig. 29 Mode Hub Removal

1 - MAINSHAFT
2 - MODE HUB

Fig. 30 Drive Sprocket Removal

1 - DRIVE SPROCKET
2 - MAINSHAFT

INPUT GEAR AND LOW RANGE GEAR REMOVAL

(1) Remove front bearing retainer attaching bolts (Fig. 31).

(2) Remove front bearing retainer. Pry retainer loose with pry tool positioned in slots at each end of retainer (Fig. 32).

Fig. 31 Front Bearing Retainer Bolts

1 - FRONT CASE
2 - FRONT BEARING RETAINER
3 - RETAINER BOLTS

Fig. 32 Front Bearing Retainer Removal

1 - FRONT BEARING RETAINER
2 - RETAINER SLOT

(3) Remove front bearing retainer seal. Tap seal out with drift and hammer.

(4) Remove input gear retaining ring with heavy duty snap-ring pliers (Fig. 33)

Fig. 33 Removing Input Gear Retaining Ring

1 - INPUT GEAR BEARING RETAINING RING
2 - INPUT GEAR BEARING
3 - SNAP RING PLIERS

(5) Place front case in horizontal position. Then remove input gear and low range gear as an assembly (Fig. 34). Tap gear out of bearing with plastic mallet if necessary.

Fig. 34 Input Gear And Planetary Carrier Removal

1 - PLANETARY ASSEMBLY
2 - INPUT GEAR

INPUT AND LOW RANGE GEAR DISASSEMBLY

(1) Remove snap-ring that retains input gear in low range gear (Fig. 35).

(2) Remove retainer (Fig. 36).

(3) Remove front tabbed thrust washer (Fig. 37).

(4) Remove input gear (Fig. 38).

(5) Remove rear tabbed thrust washer from low range gear (Fig. 39).

Fig. 35 Input Gear Snap-Ring Removal

1 - CARRIER LOCK RETAINING RING
2 - INPUT GEAR
3 - PLANETARY CARRIER
4 - SCREWDRIVER

Fig. 36 Input Gear Retainer Removal

1 - INPUT GEAR
2 - LOW RANGE GEAR
3 - RETAINER

Fig. 37 Front Tabbed Thrust Washer Removal

1 - FRONT TABBED THRUST WASHER

Fig. 38 Input Gear Removal

1 - INPUT GEAR
2 - LOW RANGE GEAR

Fig. 39 Rear Tabbed Thrust Washer Removal

1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER

ASSEMBLY

Lubricate transfer case components with Mopart Dexron II automatic transmission fluid or petroleum jelly (where indicated) during assembly.

BEARING AND SEAL INSTALLATION

CAUTION: The bearing bores in various transfer case components contain oil feed holes. Make sure replacement bearings do not block the holes.

(1) Remove the front output shaft seal from case with pry tool (Fig. 40).

(2) Remove the front output shaft bearing retaining ring with screwdriver (Fig. 41).

(3) Remove bearing with Tool Handle C-4171 and Tool 5065 (Fig. 42).

Fig. 40 Front Output Seal Removal

1 - OUTPUT SHAFT SEAL
2 - PRYBAR

Fig. 41 Front Output Shaft Bearing Retaining Ring Removal

1 - SCREWDRIVERS
2 - SNAP RING
3 - FRONT OUTPUT SHAFT BEARING
4 - FRONT CASE

Fig. 42 Front Output Shaft Bearing Removal

1 - FRONT CASE
2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL 5065

(4) Install front output shaft front bearing in case with Tool Handle C-4171 and Installer 5064 (Fig. 43).

Fig. 43 Front Output Shaft Bearing Insta

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064

(5) Install output shaft front bearing retaining ring (Fig. 44). Start ring into place by hand. Then use small screwdriver to work ring into case groove.

Be sure ring is fully seated before proceeding.

Fig. 44 Installing Output Shaft Front Bearing Retaining Ring

1 - WORK RETAINING RING INTO BORE GROOVE WITH SMALL SCREWDRIVER

(6) Install new front output seal in front case with Installer Tool 8143 as follows: (a) Place new seal on tool. Garter spring on seal goes toward interior of case.

(b) Start seal in bore with light taps from hammer (Fig. 45). Once seal is started, continue tapping seal into bore until installer tool bottoms against case.

Fig. 45 Front Output Seal Installation

1 - INSTALLER 8143
2 - TRANSFER CASE

(7) Remove the output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 46).

(8) Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 47). The bearing bore is chamfered at the top. Install the bearing so it is flush with the lower edge of this chamfer (Fig. 48).

Fig. 46 Output Shaft Rear Bearing Removal

1 - REAR CASE
2 - SPECIAL TOOL L-4454-1 AND L-4454-3
3 - SPECIAL TOOL 8148

Fig. 47 Output Shaft Rear Bearing Installation

1 - HANDLE C-4171
2 - OUTPUT SHAFT INNER BEARING
3 - INSTALLER 5066

Fig. 48 Output Shaft Rear Bearing Installation Depth

1 - BEARING (SEATED) AT LOWER EDGE OF CHAMFER
2 - CHAMFER

(9) Using Remover C-4210 and Handle C-4171, drive input shaft bearing from inside the annulus gear opening in the case. (Fig. 49).

Fig. 49 Input Shaft Bearing Removal

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL C-4210

(10) Install locating ring on new bearing.

(11) Position case so forward end is facing upward.

(12) Using Remover C-4210 and Handle C-4171, drive input shaft bearing into case. The bearing locating ring must be fully seated against case surface (Fig. 50).

(13) Remove input gear pilot bearing by inserting a suitably sized drift into the splined end of the input gear and driving the bearing out with the drift and a hammer (Fig. 51).

(14) Install new pilot bearing with Installer 5065 and Handle C-4171 (Fig. 52).

Fig. 50 Seating Input Shaft Bearing

1 - SNAP RING
2 - INPUT SHAFT BEARING

Fig. 51 Remove Input Gear Pilot Bearing

1 - DRIFT
2 - INPUT GEAR

(15) Remove front bearing retainer seal with suitable pry tool.

(16) Install new front bearing retainer seal with Installer 7884 (Fig. 53).

(17) Remove seal from oil pump housing with a suitable pry tool

Fig. 52 Install Input Gear Pilot Bearing

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5065
3 - INPUT GEAR

Fig. 53 Install Front Bearing Retainer Seal

1 - FRONT BEARING RETAINER
2 - SPECIAL TOOL 7884

(18) Install new seal in oil pump housing with Installer 7888 (Fig. 54).

Fig. 54 Oil Pump Seal Installation

1 - HOUSING SEAL
2 - SPECIAL TOOL 7888
3 - OIL PUMP FEED HOUSING

(19) Remove rear retainer bearing with Installer 8128 and Handle C-4171.

(20) Install rear bearing in retainer with Handle C-4171 and Installer 5064 (Fig. 55).

Fig. 55 Installing Rear Bearing In Retainer

1 - SPECIAL TOOL C-4171
2 - SPECIAL TOOL 5064
3 - REAR RETAINER

INPUT AND LOW RANGE GEAR ASSEMBLY

(1) Lubricate gears and thrust washers (Fig. 56) with recommended transmission fluid.

(2) Install first thrust washer in low range gear (Fig. 56). Be sure washer tabs are properly aligned in gear notches.

(3) Install input gear in low range gear. Be sure input gear is fully seated.

(4) Install remaining thrust washer in low range gear and on top of input gear. Be sure washer tabs are properly aligned in gear notches.

(5) Install retainer on input gear and install snapring.

Fig. 56 Input/Low Range Gear Components

1 - SNAP RING
2 - RETAINER PLATE
3 - INPUT GEAR
4 - LOW RANGE GEAR
5 - THRUST WASHERS

INPUT GEAR AND LOW RANGE GEAR INSTALLATION

(1) Align and install low range/input gear assembly in front case (Fig. 57). Be sure low range gear pinions are engaged in annulus gear and that input gear shaft is fully seated in front bearing.

(2) Install snap-ring to hold input/low range gear into front bearing (Fig. 58).

(3) Clean gasket sealer residue from retainer and inspect retainer for cracks or other damage.

(4) Apply a 3 mm (1/8 in.) bead of Mopart gasket maker or silicone adhesive to sealing surface of retainer.

(5) Align cavity in seal retainer with fluid return hole in front of case.

CAUTION: Do not block fluid return cavity on sealing surface of retainer when applying MoparT gasket maker or silicone adhesive sealer. Seal failure and fluid leak can result.

(6) Install bolts to hold retainer to transfer case (Fig. 59). Tighten to 21 N·m (16 ft. lbs.) of torque.

Fig. 57 Input/Low Range Gear Installation

1 - ANNULUS GEAR
2 - INPUT/LOW RANGE GEAR

Fig. 58 Install Snap-Ring

1 - INPUT GEAR
2 - SNAP RING

MAINSHAFT ASSEMBLY

(1) Lubricate mainshaft splines with recommended transmission fluid.

(2) Slide drive sprocket onto mainshaft.

(3) Slide mode hub onto mainshaft.

(4) Install mode hub retaining ring. Verify that the retaining ring is fully seated in mainshaft groove.

SHIFT FORKS AND MAINSHAFT INSTALLATION

(1) Install new sector shaft O-ring and bushing (Fig. 60).

(2) Install shift sector in case (Fig. 61). Lubricate sector shaft with transmission fluid before installation.

Fig. 59 Install Front Bearing Retainer

1 - FRONT BEARING RETAINER

Fig. 60 Sector O-Ring And Bushing Installation

1 - SECTOR BUSHING
2 - O-RING

(3) Install range lever, washer, and nut on sector shaft (Fig. 62). Tighten range lever nut to 27-34 N.m (20-25 ft. lbs.) torque.

(4) Assemble and install range fork and hub (Fig.

63). Be sure hub is properly seated in low range gear and engaged to the input gear.

(5) Align and insert range fork pin in shift sector slot.

(6) Install assembled mainshaft (Fig. 64). Be sure shaft is seated in pilot bearing and input gear.

(7) Install new pads on mode fork if necessary.

Fig. 61 Shift Sector Installation

1 - SHIFT SECTOR

Fig. 62 Range Lever Installation

1 - RANGE LEVER
2 - LEVER NUT

Fig. 63 Install Range Fork And Hub Assembly

1 - RANGE HUB
2 - RANGE FORK

Fig. 64 Mainshaft Assembly Installation

1 - DRIVE SPROCKET
2 - MODE HUB
3 - MAINSHAFT

(8) Insert mode sleeve in mode fork mode fork. Be sure long side of sleeve is toward long end of shift rail (Fig. 65).

Fig. 65 Assembling Mode Fork And Sleeve

1 - MODE SLEEVE
2 - MODE FORK AND RAIL

(9) Install assembled mode fork and sleeve (Fig.

66). Be sure fork rail goes through range fork and into case bore. Also be sure sleeve is aligned and seated on mainshaft hub.

(10) Rotate sector to Neutral position.

(11) Install new O-ring on detent plug (Fig. 67).

(12) Lubricate detent plunger with transmission fluid or light coat of petroleum jelly.

(13) Install detent plunger, spring and plug (Fig.

67).

(14) Verify that plunger is properly engaged in sector.

FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION

(1) Lubricate front output shaft-sprocket assembly, drive chain, and drive sprocket with transmission fluid.

Fig. 66 Mode Fork And Sleeve Installation

1 - MODE SLEEVE
2 - MODE FORK AND RAIL

Fig. 67 Shift Detent Components

1 - POPPET
2 - SPRING
3 - SCREW
4 - POPPET BORE (IN CASE)

(2) Assemble drive chain and front output shaft (Fig. 68).

(3) Start chain on mainshaft drive sprocket.

(4) Guide front shaft into bearing and drive sprocket onto mainshaft drive gear (Fig. 68).

(5) Install mode spring on upper end of mode fork shift rail (Fig. 69).

OIL PUMP AND REAR CASE ASSEMBLY/INSTALLATION

(1) Install magnet in front case pocket (Fig. 70).

(2) Assemble oil pickup screen, connecting hose, and tube.

(3) Install new pickup tube O-ring in oil pump (Fig. 71).

Fig. 68 Installing Drive Chain And Front Output Shaft

1 - FRONT OUTPUT SHAFT
2 - DRIVE CHAIN
3 - MAINSHAFT
4 - DRIVE SPROCKET

Fig. 69 Install Mode Fork Spring

1 - MODE SPRING

(4) Insert oil pickup tube in oil pump inlet.

(5) Position assembled oil pump and pickup tube in rear case. Be sure pickup screen is securely seated in case slot. Also be sure oil pump locating tabs are outside rear case (Fig. 72).

(6) 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.

Fig. 70 Installing Case Magnet

1 - MAGNET

Fig. 71 Pickup Tube O-Ring Position

1 - OIL PUMP
2 - O-RING

(7) Lift rear case and oil pump and carefully position assembly on front case. Be sure case dowels are aligned and that mode fork rail extends through rear case before seating rear case on front case.

(8) Install case attaching bolts. Alignment bolts at each end of case are only ones requiring washers (Fig. 73).

(9) Tighten case bolts to 27-34 N·m (20-25 ft. lbs.) torque.

YOKE AND RANGE LEVER INSTALLATION

(1) Install indicator switch in front case. Tighten switch to 20-34 N·m (15-25 ft. lbs.) torque.

Fig. 72 Oil Pump And Pickup Tube Installation

1 - OIL PUMP
2 - PICKUP TUBE
3 - PICKUP SCREEN AND CONNECTOR

Fig. 73 Alignment Bolt Location

1 - ALIGNMENT BOLT AND WASHER (AT EACH END OF CASE)

(2) Install range lever, washer and locknut on sector shaft (Fig. 74). Tighten locknut to 27-34 N·m (20-25 ft. lbs.) torque.

(3) Install new seal washer on front output shaft (Fig. 76).

(4) Lubricate yoke hub with transmission fluid and install yoke on front shaft.

(5) Install new seal washer on front shaft.

(6) Install yoke and new yoke nut on front output shaft (Fig. 75).

(7) Tighten yoke nut to 122-176 N·m (90-130 ft.

lbs.) torque. Use Tool C-3281, or similar tool to hold yoke while tightening yoke nut.

REAR RETAINER INSTALLATION

(1) Apply bead of Mopart Sealer P/N 82300234, or Loctitey Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch.

(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.

Fig. 74 Range Lever Installation

1 - RANGE LEVER
2 - WASHER
3 - LOCKNUT

Fig. 75 Output Shaft Yoke Installation

1 - OUTPUT SHAFT YOKE
2 - YOKE NUT

Fig. 76 Yoke Seal Washer Installation

1 - YOKE SEAL WASHER

(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. 77).

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. 78).

Fig. 77 Output Shaft Seal and Protector

1 - OUTPUT SHAFT SEAL
2 - SPECIAL TOOL 6992
3 - TRANSFER CASE

Fig. 78 Rear Seal Installation

1 - SPECIAL TOOL C-4076-B
2 - SPECIAL TOOL MD998323
3 - TRANSFER CASE

(7) Install rear slinger with Installer 8408.

(8) Install boot on output shaft slinger and crimp retaining clamp with tool C-4975-A (Fig. 79).

Fig. 79 Slinger Boot Installation

1 - SPECIAL TOOL C-4975-A
2 - SLINGER
3 - BOOT
4 - CLAMP