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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 >> Shift Forks And MAINSHAFT

Shift Forks And MAINSHAFT

WARNING: This page is about a different variant/trim than selected.
  1. Lubricate mainshaft splines with recommended transmission fluid.
  2. Install the drive sprocket drive hub onto the mainshaft. Verify that the long shoulder is towards the front of the mainshaft.
    Fig 1: Installing Drive Sprocket Drive Hub
    G01708099Courtesy of DAIMLERCHRYSLER CORP.
  3. Install the mode hub onto the mainshaft.
    Fig 2: Installing Mode Hub
    G01708100Courtesy of DAIMLERCHRYSLER CORP.
  4. Install the mode hub snap-ring onto the mainshaft.
    Fig 3: Installing Mode Hub Snap Ring
    G01708101Courtesy of DAIMLERCHRYSLER CORP.
  5. Rotate the mainshaft 180° and install the sliding clutch gear onto the drive sprocket drive hub.
    Fig 4: Installing Sliding Clutch Gear
    G01708102Courtesy of DAIMLERCHRYSLER CORP.
  6. Install the mainshaft drive sprocket onto the drive hub.
    Fig 5: Installing Mainshaft Drive Sprocket
    G01708103Courtesy of DAIMLERCHRYSLER CORP.
  7. Install the mainshaft drive sprocket retaining ring onto the drive hub.
    Fig 6: Installing Mainshaft Drive Sprocket Snap Ring
    G01708104Courtesy of DAIMLERCHRYSLER CORP.
  8. Support front case on wood blocks so case interior is facing up. Place blocks between mounting studs on forward surface of case.
  9. Lubricate mainshaft components with transmission fluid.
  10. Lubricate sector shaft with transmission fluid and install shift sector in case. Position slot in sector so it will be aligned with shift fork pin when shift forks are installed.
    Fig 7: Installing Shift Sector
    G01708105Courtesy of DAIMLERCHRYSLER CORP.
  11. Assemble and install range fork and hub. Be sure hub is properly seated in low range gear and engaged to the input gear.
    Fig 8: Installing Range Fork & Hub
    G01708106Courtesy of DAIMLERCHRYSLER CORP.
  12. Align and insert range fork pin in shift sector slot.
  13. Install mode fork and mode sleeve. Verify that the long side of the mode sleeve is towards the front of the transfer case.
    Fig 9: Installing Mode Fork & Sleeve
    G01708107Courtesy of DAIMLERCHRYSLER CORP.
  14. Install the shift rail through the shift forks and into the shift rail pocket in the front case half.
    Fig 10: Installing Shift Fork Rail
    G01708108Courtesy of DAIMLERCHRYSLER CORP.
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