Part 2 of 2

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.

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 and seal washer as neither part should be reused.

Inspect the shaft threads, sprocket teeth, and bearing surfaces. Minor nicks on the teeth can be smoothed with an oilstone. Use 320-400 grit emery to smooth minor scratches on the shaft bearing surfaces. Rough threads on the shaft can be chased if necessary. Replace the shaft if the threads are damaged, bearing surfaces are scored, or if any sprocket teeth are cracked or broken.

Examine the drive chain and shaft bearings. Replace the chain and both sprockets if the chain is stretched, distorted, or if any of the links bind. Replace the bearings if rough, or noisy.

LOW RANGE ANNULUS GEAR





Inspect annulus gear condition carefully. The gear is only serviced as part of the front case. If the gear is damaged, it will be necessary to replace the gear and front case as an assembly. Do not attempt to remove the gear (Fig. 50)

FRONT/REAR CASES AND FRONT RETAINER
Inspect the cases and retainer for wear and damage. Clean the sealing surfaces with a scraper and 3M all purpose cleaner. This will ensure proper sealer adhesion at assembly. Replace the input retainer seal; do not reuse it.

Check case condition. If leaks were a problem, look for gouges and severe scoring of case sealing surfaces. Also make sure the front case mounting studs are in good condition.

Check the front case mounting studs and vent tube. The tube can be secured with Loctite 271 or 680 if loose. The stud threads can be cleaned up with a die if necessary. Also check condition of the fill/ drain plug threads in the rear case. The threads can be repaired with a thread chaser or tap if necessary. Or the threads can be repaired with Helicoil stainless steel inserts if required.

OIL PUMP/OIL PICKUP
Examine the oil pump pickup parts. Replace the pump if any part appears to be worn or damaged. Do not disassemble the pump as individual parts are not available. The pump is only available as a complete assembly. The pickup screen, hose, and tube are the only serviceable parts and are available separately.

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

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

BEARING AND SEAL





1. Remove snap-ring that retains front output shaft front bearing in case (Fig. 51). Then remove bearing. Use hammer handle, or hammer and brass punch to tap bearing out of case.





2. Install new front output shaft front bearing with Tool Handle C-4171 and Installer 8033-A with the tapered cone upward (Fig. 52).
3. Install front bearing snap-ring (Fig. 51).





4. Remove front output shaft seal using an appropriate pry tool (Fig. 53) or slide-hammer mounted screw.





5. Install new front output shaft oil seal with Installer 6952-A (Fig. 54).





6. Remove input gear bearing with Tool Handle C-4171 and Remover C-4210 (Fig. 55).
7. Install snap-ring on new input gear bearing.





8. Install new input gear bearing with Tool Handle C-4171 and Remover C-4210. Install bearing far enough to seat snap-ring against case (Fig. 56).





9. Remove the 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. 57).





10. Install new pilot bearing with Installer 8128 and Handle C-4171 (Fig. 58).





11. Install new seal in front bearing retainer with Installer 7884 (Fig 59)





12. Remove output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148 (Fig. 60).





13. Install new bearing with Tool Handle C-4171 and Installer 5066 (Fig. 61). Lubricate bearing after installation.





14. Install new seal in oil pump feed housing with Special Tool 7888 (Fig. 62).





15. Install new pickup tube O-ring in oil pump (Fig. 63).
16. Remove rear retainer bearing with Installer 8128 and Handle C-4171, NV242HD only.





17. Install rear bearing in retainer with Handle C-4171 and Installer 5064 (Fig. 64), NV242HD only.

DIFFERENTIAL
1. Lubricate differential components with automatic transmission fluid.





2. Install sprocket gear in differential bottom case (Fig. 65).





3. Install differential planet gears and new thrust washers (Fig. 66). Be sure thrust washers are installed at top and bottom of each planet gear.
4. Install differential mainshaft gear (Fig. 66).





5. Align and position differential top case on bottom 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 Mopar gasket 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 Nm) torque.

SHIFT FORKS, SECTOR, AND MAINSHAFT
1. Install the shift sector shaft O-ring and bushing.
2. Install shift sector.
3. Install new pads on low range fork, if necessary.
4. Assemble low range fork and sleeve.
5. Position low range fork and sleeve in case. Be sure low range fork pin is engaged in shift sector slot.





6. Install first mainshaft bearing spacer on mainshaft (Fig. 72).
7. Install bearing rollers on mainshaft (Fig. 72). Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
8. Install remaining bearing spacer on mainshaft (Fig. 72). Do not displace any bearings while installing spacer.





9. Install differential (Fig. 73). Do not displace mainshaft bearings when installing differential.





10. Install differential snap-ring (Fig. 74).





11. Install intermediate clutch shaft (Fig. 75).





12. Install clutch shaft thrust washer (Fig. 76).





13. Install clutch shaft snap-ring (Fig. 77).





14. Inspect mode fork assembly (Fig. 78). Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket (Fig. 78). Replace worn, damaged components.





15. Install mode sleeve in mode fork (Fig. 79). Then, install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.





16. Install mode fork and mainshaft assembly in case (Fig. 80). Rotate mainshaft slightly to engage shaft with low range gears.
17. Rotate mode fork pin into shift sector slot.





18. Install shift rail (Fig. 81). Be sure rail is seated in both shift forks.
19. Rotate shift sector to align lockpin hole in low range fork with access hole in case.
20. Insert an easy-out in range fork lockpin to hold it securely for installation (Fig. 82). Lockpin is slightly tapered on one end. Insert tapered end into fork and rail.





21. Insert lockpin through access hole and into shift fork (Fig. 82). Then remove easy-out and seat the pin with pin punch.
22. Install plug in lockpin access hole.





23. Install detent plunger, detent spring and detent plug in case (Fig. 83).

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 Mopar gasket 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 mainshaft splines are engaged in oil pump inner gear.
5. Install and tighten front case-to-rear case bolts to 41 Nm (30 ft. lbs.) torque. Be sure to install a washer under each bolt used at case dowel locations.

REAR RETAINER - NV242LD
1. Apply bead of Mopar Sealer, or Loctite 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 Nm (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).

NV242HD REAR RETAINER
1. Apply bead of Mopar Sealer, or Loctite 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 Nm (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 Mopar gasket 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 Nm (26 - 34 ft. lbs.).

COMPANION FLANGE
1. Lubricate companion flange hub with transmission 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 Nm (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 Nm (26 ft. lbs.) torque (Fig. 4).
6. Align and connect propeller shafts.
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 Nm (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.