Removing Front Output Shaft; Detent Component Removal; Shift Rail Removal; Mode Fork And Mainshaft Removal - Jeep 200 Cherokee Service Manual

21 - 384 NV242 TRANSFER CASE
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 25 Removing Front Output Shaft
1 – FRONT OUTPUT SHAFT
Fig. 26 Detent Component Removal
1 – PLUNGER
2 – O-RING
3 – PLUG
4 – SPRING
(c) Install a t-handle, such as from a tap and die
set, onto the easy-out tool.
(d) Securely tighten the t-handle onto the tool.
(e) In one motion, pull upward and turn the
t-handle counter-clockwise to remove the lock-pin.
(4) Remove shift rail by pulling it straight up and
out of fork (Fig. 27).
(5) Remove mode fork and mainshaft as assembly
(Fig. 28).
(6) Remove mode shift sleeve and mode fork
assembly from mainshaft (Fig. 29). Note position of
mode sleeve in fork and remove sleeve.
Fig. 27 Shift Rail Removal
1 – SHIFT RAIL
2 – MODE FORK
Fig. 28 Mode Fork And Mainshaft Removal
1 – MAINSHAFT ASSEMBLY
2 – MODE FORK
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