Chrysler Vehicle User Manual page 1368

TJ
TRANSFER CASE - NV241 (Continued)
Condition
Transfer Case noisy in all operating
ranges.
Noisy in, or jumps out of, four wheel
drive low range.
Lubricant leaking from output shaft
seal or vent.
Abnormal tire wear.
REMOVAL
(1) Raise and support vehicle.
(2) Remove skid plate, if equipped. (Refer to 13 -
FRAMES & BUMPERS/FRAME/TRANSFER CASE
SKID PLATE - REMOVAL)
(3) Position drain oil container under transfer
case.
(4) Remove transfer case drain plug and drain
lubricant into container.
(5) Disconnect vent hose and vacuum harness at
transfer case switch.
(6) Disconnect shift rod from grommet in transfer
case shift lever, or from floor shift arm whichever
provides easy access. Use channel lock style pliers to
press rod out of lever grommet.
(7) Support transmission with jack stand.
(8) Remove rear crossmember.
(9) Mark front and rear propeller shafts for assem-
bly reference.
Possible Cause
1) Insufficient or incorrect lubricant.
1) Transfer case not completely
engaged in 4L position.
2) Shift linkage out of adjustment.
3) Shift linkage loose or binding.
4) Range fork damaged, inserts
worn, or fork is binding on the shift
rail.
5) Low range gear worn or
damaged.
1) Transfer case overfilled.
2) Vent closed or restricted.
3) Output shaft seals damaged or
installed incorrectly.
1) Extended operation on hard, dry
surfaces in the 4H position.
(10) Remove front and rear propeller shafts. (Refer
to 3 - DIFFERENTIAL & DRIVELINE/PROPELLER
SHAFT/PROPELLER SHAFT - REMOVAL)
(11) Support transfer case with suitable jack.
Secure transfer case to jack with safety chains.
(12) Remove nuts attaching transfer case to trans-
mission.
(13) Move transfer case assembly rearward until
free of transmission output shaft.
(14) Lower jack and move transfer case from
under vehicle.
DISASSEMBLY
Position transfer case in a shallow drain pan.
Remove drain plug and drain any remaining lubri-
cant remaining in case.
TRANSFER CASE - NV241
Correction
1) Drain and refill to edge of fill hole
with Mopar ATF +4, type 9602,
Automatic Transmission fluid.
1) With the transmission in
NEUTRAL, or the clutch depressed
in the case of a manual
transmission and the vehicle moving
under 3-4 km/h (2-3 mph), shift the
transfer case to NEUTRAL and then
shift into the 4L position.
2) Adjust linkage.
3) Tighten, lubricate, or repair
linkage as necessary.
4) Disassemble unit and repair as
necessary.
5) Disassemble unit and repair as
necessary.
1) Drain lubricant to the correct
level.
2) Clear or replace vent as
necessary.
3) Replace seal as necessary.
Check to ensure that another
component, the propeller shaft slip
yoke for example, is not causing
damage to seal.
1) Operate vehicle in the 2H
position on hard, dry surfaces.
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