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Home >> Jeep >> 2004 >> Wrangler Sport, Automatic >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 2 (Overhaul - NV241 Transfer Case) >> Transfer Case - NV241 >> Assembly >> Front Output Shaft And Drive Chain

Front Output Shaft And Drive Chain

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  1. Install front output shaft into the font output shaft bearing.
    Fig 1: Installing Front Output Shaft
    G01708109Courtesy of DAIMLERCHRYSLER CORP.
  2. Install the front output shaft snap-ring onto the front output shaft.
  3. Install new front output seal in front case with Installer 9041 and Handle C-4171.
    Fig 2: Installing Front Output Shaft Seal
    G01708110Courtesy of DAIMLERCHRYSLER CORP.
  4. Insert front sprocket in drive chain.
    Fig 3: Installing Mainshaft, Drive Chain & Front Sprocket
    G01708111Courtesy of DAIMLERCHRYSLER CORP.
  5. Install drive chain around mainshaft drive sprocket. See Fig 3 . Then position front sprocket over front output shaft.
  6. Install the mainshaft into the range hub and mode sleeve and seat the front drive sprocket onto the front output shaft. See Fig 3 .
  7. Install the front drive sprocket retaining ring.
    Fig 4: Installing Front Drive Sprocket Snap Ring
    G01708112Courtesy of DAIMLERCHRYSLER CORP.
  8. Install spring and cups on shift rail.
    Fig 5: Installing Shift Rail Spring & Cups
    G01708113Courtesy of DAIMLERCHRYSLER CORP.
  9. Insert magnet in front case pocket.
    Fig 6: Installing Case Magnet
    G01708114Courtesy of DAIMLERCHRYSLER CORP.
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