Assembly
ASSEMBLY / NV242 Transfer CaseNOTE: 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.
BEARINGS AND SEALS
1. Remove snap-ring that retains front output shaft front bearing in case. 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.
3. Install front bearing snap-ring.
4. Remove front output shaft seal using an appropriate pry tool or slide-hammer mounted screw.
5. Install new front output shaft oil seal with Installer 6952-A.
6. Remove input gear bearing with Tool Handle C-4171 and Remover C-4210.
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.
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.
10. Install new pilot bearing with Installer 8128 and Handle C-4171.
11. Install new seal in front bearing retainer with Installer 7884.
12. Remove output shaft rear bearing with the screw and jaws from Remover L-4454 and Cup 8148.
13. Install new bearing with Tool Handle C-4171 and Installer 5066. Lubricate bearing after installation.
14. Install new seal in oil pump feed housing with Special Tool 7888.
15. Install new pickup tube O-ring in oil pump .
DIFFERENTIAL
1. Lubricate differential components with automatic transmission fluid.
2. Install sprocket gear in differential bottom case .
3. Install differential planet gears and new thrust washers. Be sure thrust washers are installed at top and bottom of each planet gear.
4. Install differential mainshaft gear.
5. Align and position differential top case on bottom case. 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.
Differential Case Bolts 17 - 27 Nm (15 - 24 ft. lbs.)
INPUT GEAR / LOW RANGE ASSEMBLY
1. Assemble low range gear, input gear thrust washers, input gear and input gear retainer.
2. Install low range gear snap-ring.
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.
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.
Front Bearing Retainer Bolts 24 ft. lbs. (21 Nm)
SHIFT FORKS, SECTOR, AND MAINSHAFT
1. Install the shift sector shaft bearing using a suitable socket until the bearing is flush to the bottom, inner edge of the bore.
2. Install a new shift sector shaft seal using a suitable socket until the seal is flush to the bottom of the bore lead-in chamfer.
3. Install shift sector.
4. Install new pads on low range fork, if necessary.
5. Assemble low range fork and sleeve.
6. Position low range fork and sleeve in case. Be sure low range fork pin is engaged in shift sector slot.
7. Install first mainshaft bearing spacer on mainshaft.
8. Install bearing rollers on mainshaft. Coat bearing rollers with generous quantity of petroleum jelly to hold them in place.
9. Install remaining bearing spacer on mainshaft. Do not displace any bearings while installing spacer.
10. Install differential. Do not displace mainshaft bearings when installing differential.
11. Install differential snap-ring.
12. Install intermediate clutch shaft.
13. Install clutch shaft thrust washer.
14. Install clutch shaft snap-ring.
15. Inspect mode fork assembly. Replace pads and bushing if necessary. Replace fork tube if bushings inside tube are worn or damaged. Also check springs and slider bracket. Replace worn, damaged components.
16. Install mode sleeve in mode fork . Then install assembled sleeve and fork on mainshaft. Be sure mode sleeve splines are engaged in differential splines.
17. Install mode fork and mainshaft assembly in case. Rotate mainshaft slightly to engage shaft with low range gears.
18. Rotate mode fork pin into shift sector slot.
19. Install shift rail. Be sure rail is seated in both shift forks.
20. Rotate shift sector to align lockpin hole in low range fork with access hole in case.
21. Insert an easy-out in range fork lockpin to hold it securely for installation. Lockpin is slightly tapered on one end. Insert tapered end into fork and rail.
22. Insert lockpin through access hole and into shift fork. Then remove easy-out and seat the pin with pin punch.
23. Install plug in lockpin access hole.
24. Install detent plunger, detent spring and detent plug in case.
FRONT OUTPUT SHAFT AND DRIVE CHAIN
1. Install front output shaft.
2. Install drive chain. Engage chain with front output shaft sprocket teeth.
3. Install drive sprocket. Engage drive sprocket teeth with chain. Then engage sprocket splines with mainshaft splines.
4. Install drive sprocket snap-ring.
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. Be sure screen is seated in case slot as shown.
2. Install magnet in front case pocket.
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. Be sure to install a washer under each bolt used at case dowel locations.
Front Case-to-Rear Case Bolts 41 Nm (30 ft. lbs.)
REAR RETAINER
1. Remove rear bearing in retainer using Installer 8128 and Handle C-4171.
2. Install rear bearing in retainer with Tools C-4171 and 5064.
3. Install rear bearing O.D. retaining ring with snap-ring pliers . Be sure retaining ring is fully seated in retainer groove.
4. Apply bead of Mopar Sealer P/N 82300234, or Loctite TM Ultra Gray, to mating surface of rear retainer. Sealer bead should be a maximum of 3/16 inch.
5. Install rear retainer on rear case.
Rear Retainer Bolts - Rear Case 20 - 27 Nm (15 - 20 ft. lbs.)
6. Install rear bearing I.D. retaining ring and spacer on output shaft.
7. Apply liberal quantity of petroleum jelly to new rear seal and to output shaft. Petroleum jelly is needed to protect seal lips during installation.
8. Slide seal onto Seal Protector 6992. Slide seal protector and seal onto output shaft.
9. 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.
10. Install rear slinger with Installer 8408.
11. Install boot on output shaft slinger and crimp retaining clamp with tool C-4975-A.
COMPANION FLANGE AND RANGE LEVER
1. Install range lever and bolt on sector shaft.
Range Lever Bolt 27 - 34 Nm (20 - 25 ft. lbs.)
2. Inspect the O-ring on the transfer case position sensor. Replace the O-ring if necessary.
3. Install the transfer case position sensor in the front case.
Transfer Case Position Sensor 20 - 34 Nm (15 - 25 ft. lbs.)
4. Install new seal washer on front output shaft.
5. Lubricate companion flange hub with transmission fluid and install flange onto the front output shaft.
6. Install new seal washer on front shaft.
7. Install new flange nut onto front output shaft.
8. Tighten flange nut.
Flange Nut 122 - 176 Nm (90 - 130 ft. lbs.)