Cleaning; Inspection - Jeep KJ 2005 Service Manual

KJ
TRANSFER CASE - NV241 GENII (Continued)
Fig. 38 Input Gear Removal
1 - INPUT GEAR
2 - LOW RANGE GEAR
(4) Remove input gear (1) (Fig. 38).
Fig. 39 Rear Tabbed Thrust Washer Removal
1 - LOW RANGE GEAR
2 - REAR TABBED THRUST WASHER
(5) Remove rear tabbed thrust washer (2) from low
range gear (1) (Fig. 39).

CLEANING

Clean the transfer case parts with a standard
parts cleaning solvent. Remove all traces of sealer
from the cases and retainers with a scraper and
3M™ all purpose cleaner. Use compressed air to
remove solvent residue from oil feed passages in the
case halves, retainers, gears, and shafts.

INSPECTION

MAINSHAFT/SPROCKET/HUB
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
TRANSFER CASE - NV241 GENII
be smoothed with an oilstone, however, replace any
part that is damaged.
Check the contact surfaces in the sprocket bore
and on the mainshaft. Minor nicks and scratches can
be smoothed with 320-400 grit emery cloth but do not
try to salvage the shaft if nicks or wear is severe.
INPUT GEAR AND PLANETARY CARRIER
Check the teeth on the gear (6) (Fig. 40). Minor
nicks can be dressed off with an oilstone but replace
the gear if any teeth are broken, cracked, or chipped.
The bearing surface on the gear can be smoothed
with 300-400 grit emery cloth if necessary.
Examine the carrier body (1) and pinion gears for
wear or damage. The carrier will have to be replaced
as an assembly if the body, pinion pins, or pinion
gears are damaged.
Check the lock ring (4) and both thrust washers (2,
3) for wear or cracks. Replace them if necessary. Also
replace the lock retaining ring (5) if bent, distorted,
or broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (2) (Fig. 41). Minor nicks on the shift rail
can be smoothed with 320-400 grit emery cloth.
Inspect the shift fork wear pads (3, 4) (Fig. 42).
The mode fork pads are serviceable and can be
replaced if necessary. The range fork pads are not
serviceable. The fork must be replaced as an assem-
bly if the pads are worn or damaged.
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 COMPONENTS
Inspect the retainer components. Replace the bear-
ing if rough or noisy. Check the retainer for cracks or
wear in the bearing bore.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended.
Inspect rear extension bushing. Replace if worn or
scored.
DRIVE CHAIN
Examine the drive chain and shaft bearings.
replace the chain if stretched, distorted, or if any of
the links bind. Replace the bearings if rough, or
noisy.
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