Transfer Case Removal And Installation; Transfer Case Mounting - Jeep 200 Cherokee Service Manual

21 - 348 NV231 TRANSFER CASE
DIAGNOSIS AND TESTING (Continued)
Condition
Transfer case noisy while in, or
jumps out of, 4L mode.
Lubricant leaking from transfer case
seals or vent.
Abnormal tire wear.
REMOVAL AND INSTALLATION
TRANSFER CASE
REMOVAL
(1) Shift transfer case into Neutral.
(2) Raise vehicle.
(3) Drain transfer case lubricant.
(4) Mark front and rear propeller shaft yokes for
alignment reference.
(5) Support transmission with jack stand.
(6) Remove rear crossmember, or skid plate.
(7) Disconnect front/rear propeller shafts at trans-
fer case.
(8) Disconnect vehicle speed sensor wires.
(9) Disconnect transfer case linkage rod from
range lever.
(10) Disconnect transfer case vent hose (Fig. 3)
and indicator switch harness, if necessary.
(11) Support transfer case with transmission jack.
(12) Secure transfer case to jack with chains.
(13) Remove nuts attaching transfer case to trans-
mission.
(14) Pull transfer case and jack rearward to disen-
gage transfer case.
(15) Remove transfer case from under vehicle.
INSTALLATION
(1) Mount transfer case on a transmission jack.
(2) Secure transfer case to jack with chains.
Possible Cause
1) Transfer case not completely
engaged in 4L position.
2) Transfer case shift linkage out of
adjustment.
3) Transfer case 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) Transfer case vent closed or
restricted.
3) Transfer case seals damaged or
installed incorrectly.
1) Extended operation in 4H mode
on dry surfaces,
1 – VENT TUBE
2 – TRANSFER CASE
3 – TRANSMISSION
(3) Position transfer case under vehicle.
(4) Align transfer case and transmission shafts
and install transfer case on transmission.
(5) Install and tighten transfer case attaching nuts
to 35 N·m (26 ft. lbs.) torque (Fig. 3).
(6) Connect vehicle speed sensor wires, and vent
hose.
(7) Connect indicator switch harness to transfer
case switch, if necessary. Secure wire harness to clips
on transfer case.
Correction
1) Slow vehicle, shift transfer case
to the Neutral position, and then
shift into the 4L mode.
2) Adjust linkage as necessary.
3) Repair, replace, or tighten linkage
components as necessary.
4) Repair or replace components as
necessary.
5) Repair or replace components as
necessary.
1) Drain lubricant to the correct
level.
2) Clean or replace vent as
necessary.
3) Replace suspect seal.
1) Operate vehicle in 2H mode on
dry surfaces.
Fig. 3 Transfer Case Mounting
XJ