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1993 Jeep Cherokee

1987-96 TRANSFER CASES Jeep - New Venture 2 42

Cherokee, Comanche, Wagoneer, Grand Wagoneer

IDENTIFICATION

Transfer case can be identified by an I.D. tag, located on rear case. I.D. tag provides model number, serial number and low range ratio. Date of manufacture is the serial number (I.D. number). This information is necessary when ordering parts.

DESCRIPTION

Model 242 transfer case is a chain-driven, 2-piece aluminum case, with full time operation. Torque input in 4WD high and low range is undifferentiated.

ADJUSTMENTS

GEARSHIFT LINKAGE

Remove shift boot and shift to 4L position. Loosen trunnion nut. Adjust trunnion and shift rod until rod fits freely. Tighten trunnion nut and remove shim.

TROUBLE SHOOTING

SYMPTOM DIAGNOSIS

Will Not Shift Or Difficult To Shift Into Gear

Check fluid level. Check linkage adjustment. Ensure transfer

case external linkage is not binding. Internal parts may be worn or

damaged.

Noisy In All Gears

Check fluid level. Ensure correct fluid is used. If fluid is okay, locate noise and check for possible internal mechanical problem.

Jumps Out Of Gear Or Noisy In 4WD

Transfer case not completely in gear; check shift linkage. Range fork damaged. Inserts are worn. Shift fork binding on shift rail. Low range gear worn or damaged.

Fluid Leaking From Vent Or Seals

Transfer case overfilled. Vent plugged. Output shaft seals are damaged or not installed properly.

Transfer Case Will Not Shift Through High Lock Range Incomplete shift due to driveline torque load; momentarily release accelerator pedal to complete shift. Check tire pressure and tire wear. Vehicle overloaded; remove load and check shifting.

ON-VEHICLE SERVICE

FRONT OIL SEAL

Removal & Installation

12. Mark front propeller shaft and flange for alignment
    purposes. Remove front propeller shaft. Remove flange. Discard washer
    and nut. Using a screwdriver, carefully remove oil seal. Ensure seal
    contact surface is clean.

13. Apply ATF to seal lip and yoke seal surface. Install oil
    seal and flange with new washer and nut. Install front propeller shaft
    using alignment marks. Check transfer case fluid.

EXTENSION HOUSING OIL SEAL & BUSHING

NOTE: When replacing oil seal, DO NOT remove extension housing.

Removal & Installation

12. Mark rear propeller shaft and flange for installation
    purposes. Remove rear propeller shaft. Remove bolts and tap extension
    housing in a clockwise direction and remove extension housing. DO NOT
    pry on extension housing. Using a screwdriver, remove oil seal from
    extension housing.

13. Using bushing driver, replace bushing in extension
    housing. Install new extension housing oil seal. Apply silicone
    sealant to extension housing mating surface. Install extension
    housing. Reverse removal procedure to complete installation.

REMOVAL & INSTALLATION

TRANSFER CASE

Removal & Installation

12. Shift transfer case into Neutral position and drain fluid.
    Mark front and rear drive shaft for installation purposes. Remove
    front and rear drive shafts. Disconnect vacuum lines and speedometer
    cable. Remove rear crossmember.

13. Disconnect shift linkage. Support transfer case with a
    jack. Separate transfer case from transmission. Remove transfer case.
    To install, reverse removal procedure. Tighten bolts to specification.
    See TORQUE SPECIFICATIONS. Adjust shift linkage, if necessary.

TRANSFER CASE DISASSEMBLY

1) Remove drain and fill plugs. See Fig. 1. Remove front
companion flange, washer and seal. Place transfer case in 4L position.
Remove extension housing. See EXTENSION HOUSING OIL SEAL & BUSHING
under ON-VEHICLE SERVICE. Remove rear bearing snap ring. Remove rear
bearing retainer. Separate rear case from front case using prybars or
screwdriver. DO NOT damage mating surfaces.

NOTE: DO NOT disassemble oil pump, replace as unit only.

12. Remove oil pump, pick-up tube and screen from rear case.
    Remove pick-up tube "O" ring from oil pump. Remove magnet from front
    case. Remove drive sprocket snap ring. Remove drive sprocket and drive
    chain.

13. Remove front output shaft. Remove shift lever from sector
    shaft. Remove shift detent plug, spring and plunger. Remove plug from
    low range fork lock pin access hole. Move shift sector until lock pin
    is aligned with hole. Remove lock pin with No. 1 screw extractor.

14. Remove shift rail from fork assembly. Remove mode fork and
    mainshaft as an assembly. Record mode sleeve position. Remove mode
    shift sleeve and mode fork assembly. Remove sleeve from fork. Remove

intermediate clutch shaft snap ring from mainshaft.

12. Remove clutch shaft thrust ring. Remove intermediate
    clutch shaft. Remove differential retaining snap ring. Remove
    differential assembly. Remove differential needle bearings and thrust
    washers from mainshaft. Remove low range fork and hub.

13. Remove shift sector. Remove shift sector bushing and "O"
    ring. Remove front bearing retainer. Remove input gear snap ring.
    Using a press, remove input and low range gear assembly from input
    gear bearing. Remove low range gear snap ring.

14. Remove input gear retainer, thrust washers and input gear.
    Mark differential halves for reassembly purposes. Separate
    differential halves. Remove planetary gear and thrust washers.

15. Record mainshaft gear and sprocket gear position. Remove
    gears. Remove front output shaft front bearing oil seal, snap ring and
    front bearing. Using a press, remove input gear bearing.

16. Using slide hammer and internal puller, remove input gear
    pilot bearing. Using slide hammer and internal puller, remove front
    output shaft rear bearing.

12. Front Bearing Retainer & Seal

13. Front Case

14. Shift Sector

15. Low Range Fork & Inserts

16. Shift Rail

17. Shift Bracket

18. Slider Bracket

19. Bushing & Spring

20. Mode Fork & Inserts

12. Bushing

13. Fork Spring

14. Bushing

15. Vent Tube

16. Input Gear Bearing & Snap Ring

17. Low Range Gear Snap Ring

16 Low Range Gear Retainer

12. Low Range Gear Thrust Washer

13. Input Gear

14. Rear Case

15. Drain & Fill Plugs

16. Rear Bearing Retainer

17. Extension Housing

18. Bushing & Oil Seal

19. Vacuum Switch(lf Equipped)

20. Magnet

21. Thrust Ring

22. Snap Ring
    28 Shift Sleeve

12. Low Range Gear

13. Pilot Bushing

12. Front Output Shaft Front
    Bearing & Snap Ring

13. Intermediate Clutch Shaft

14. Shift Sleeve

15. Snap Ring

16. Mainshaft

17. Differential Assembly

18. Oil Pick-Up Tube "O" Ring

19. Oil Pick-Up Tube & Screen

20. Mainshaft Bearing Rollers

21. Drive Sprocket

22. Drive Chain

23. Snap Ring

24. Oil Pump Seal

12. Oil Pump

13. Rear Bearing & Snap Ring

14. Front Output Shaft
    Rear Bearing

15. Snap Ring

16. Driven Sprocket

17. Front Output Shaft

18. Mainshaft Bearing Spacers

19. Shift Lever Washer & Nut

20. Shift Lever

21. Sector "O" Ring & Seal

22. Detent Pin, Spring & Plug

23. Seal Plug

24. Companion Flange, Nut, Seal,
    Washer & Oil Slmger

12. Clean all parts with solvent. Dry with compressed air.
    Replace all oil seals, "O" rings and snap rings. Check all parts for
    wear or damage. Replace all worn or damaged parts. Apply Dexron II to
    all parts before installing.

13. Inspect low range annulus gear inside front case. If gear
    is worn or damaged, replace case and gear as an assembly. Replace oil
    pump as an assembly if any part is damaged or worn.

NOTE: When installing bearings, ensure bearing bores are aligned with oil feed holes.

TRANSFER CASE REASSEMBLY

12. Install front output shaft front bearing, snap ring and
    oil seal. Install snap ring on input gear bearing. Using a wooden
    block and press, install input gear until snap ring is against case.

13. Install input gear pilot bearing. Assemble low range gear,
    thrust washers, input gear and retainer. Install low range gear snap
    ring. Ensure snap ring is seated properly in groove.

14. Start input gear shaft through the bearing in front case.
    Using a press, install input gear shaft through bearing. Ensure
    adapter is positioned properly before pressing shaft.

NOTE: Ensure proper size tool is used to press input gear shaft; wrong size tool can damage case and thrust washers and will move pilot bearing too far into gear bore.

12. Install input gear snap ring. Install front bearing
    retainer oil seal. Apply 1/8" bead of silicone sealant to front
    bearing retainer mating surface. Install front bearing retainer on
    front case. Install sector shaft "O" ring and bushing. Install shift
    sector.

13. Install detent pin, spring and plug. Install low range
    fork pads. Assemble low range fork and hub. Ensure low range fork pin
    is engaged in shift sector slot. Install differential sprocket gear in
    lower differential case. Install planet gears and new thrust washers
    on lower case pins.

14. Ensure thrust washers are positioned on top and bottom of
    each planet gear. Install mainshaft gear. Align marks on upper and
    lower differential case. Install bolts and tighten to specifications.
    See TORQUE SPECIFICATIONS. Install needle bearing spacer on mainshaft.

15. Using petroleum jelly to hold needles, install bearings on
    mainshaft. Install other spacer. Install differential assembly. Ensure
    all needle bearings are in place. Install differential snap ring.
    Install intermediate clutch shaft. Install thrust washer and snap
    ring. Install mode shift sleeve in mode fork.

16. Install mode fork assembly on mainshaft. Ensure mode shift
    sleeve splines engage with differential splines. Install mode fork and
    mainshaft assembly in case. If necessary, rotate mainshaft slightly to
    engage mainshaft with low range components.

17. Install mode fork pin into shift sector slot. Install
    shift rail. Ensure shift rail is seated in shift forks. Rotate shift
    sector so lock pin can be installed. Install lock pin so tapered end
    is in fork and rail. Install plug. Install shift lever and nut on
    shift sector shaft.

12. Install detent plunger, spring and plug. Install front
    output shaft. Install drive chain and sprocket. Install drive sprocket
    snap ring. Install front output shaft rear bearing.

13. Install oil seal in oil pump housing. Assemble oil pump
    gears in housing. Ensure oil feed hole is aligned with hole in
    housing. Install oil pump screws. Tighten to specification. Install

"O" ring in oil pump. Install oil pick-up tube and screen. Ensure screen is properly positioned. See Fig. 2.

12. Install magnet in front case. Apply 1/8" bead of silicone
    sealant to front case mating surface. Assemble case halves together.
    Tighten to specification. Ensure mainshaft splines are engaged with
    oil pump inner gear and a washer is used on bolts at dowel locations.

13. Install rear retainer bearing in retainer. Apply 1/8"
    bead of silicone sealer and install retainer to case. Install rear
    bearing snap ring. Install extension housing. Install front companion
    flange. Install vacuum switch and drain plug. Fill transfer case with
    Dexron II.

92113084

Fig. 2: Identifying Oil Pump Screen Position Courtesy of Chrysler Motors.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS TABLE

Application

Ft. Lbs. (N.m)