TRANSFER CASE - NP/NV 242
1988 Jeep Cherokee
1987-96 TRANSFER CASES Jeep - New Venture 2 42
Cherokee, Comanche, Wagoneer, Grand Wagoneer
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.
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.
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.
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
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.
FRONT OIL SEAL
Removal & Installation
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.
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
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
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
Removal & Installation
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.
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
drain and fill plugs. See Fig. 1. Remove
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.
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
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.
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.
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.
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.
input gear retainer, thrust washers and input gear.
Mark differential halves for reassembly purposes. Separate
differential halves. Remove planetary gear and thrust washers.
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.
slide hammer and internal puller, remove input gear
pilot bearing. Using slide hammer and internal puller, remove front
output shaft rear bearing.
Front Bearing Retainer & Seal
Low Range Fork & Inserts
Bushing & Spring
Mode Fork & Inserts
Input Gear Bearing & Snap Ring
Low Range Gear Snap Ring
16 Low Range Gear Retainer
Low Range Gear Thrust Washer
Drain & Fill Plugs
Rear Bearing Retainer
Bushing & Oil Seal
Vacuum Switch(lf Equipped)
28 Shift Sleeve
Low Range Gear
Output Shaft Front
Bearing & Snap Ring
Intermediate Clutch Shaft
Oil Pick-Up Tube "O" Ring
Oil Pick-Up Tube & Screen
Mainshaft Bearing Rollers
Oil Pump Seal
Rear Bearing & Snap Ring
Front Output Shaft
Mainshaft Bearing Spacers
Shift Lever Washer & Nut
Sector "O" Ring & Seal
Detent Pin, Spring & Plug
Flange, Nut, Seal,
Washer & Oil Slmger
Fig. 1: Exploded View Of Model 242 Transfer Case Courtesy of Chrysler Motors.
CLEANING & INSPECTION
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.
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
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.
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.
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.
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
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.
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.
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.
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.
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.
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.
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.
magnet in front case. Apply 1/8" bead
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.
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
Fig. 2: Identifying Oil Pump Screen Position Courtesy of Chrysler Motors.
TORQUE SPECIFICATIONS TABLE
Ft. Lbs. (N.m)
Companion Flange Nut 90-130 (122-176)
Detent Plug 14 (19)
Drain & Fill Plug 27 (37)
Extension Housing Bolt 26 (35)
Front Bearing Retainer Bolt 12 (16)
Front Case-to-Rear Case Bolt 26-34 (35-46)
Shift Fork Set Screw 15 (20)
Transfer Case-to-Transmission 26 (35)