Mode Fork Assembly Inspection; Installing Mode Fork And Sleeve - Jeep 200 Cherokee Service Manual

21 - 398 NV242 TRANSFER CASE
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 77 Mode Fork Assembly Inspection
1 – SLIDER
2 – MODE FORK
3 – BUSHING/SPRING
4 – TUBE
5 – PADS
(15) Install mode sleeve in mode fork (Fig. 78).
Then install assembled sleeve and fork on mainshaft.
Be sure mode sleeve splines are engaged in differen-
tial splines.
(16) Install mode fork and mainshaft assembly in
case (Fig. 79). Rotate mainshaft slightly to engage
shaft with low range gears.
(17) Rotate mode fork pin into shift sector slot.
(18) Install shift rail (Fig. 80). Be sure rail is
seated in both shift forks.
(19) Rotate shift sector to align lockpin hole in low
range fork with access hole in case.
(20) Insert an easy-out in range fork lockpin to
hold it securely for installation (Fig. 81). Lockpin is
slightly tapered on one end. Insert tapered end
into fork and rail.
(21) Insert lockpin through access hole and into
shift fork (Fig. 81). Then remove easy-out and seat
the pin with pin punch.
Fig. 78 Installing Mode Fork And Sleeve
1 – MAINSHAFT
2 – SLEEVE
3 – MODE FORK ASSEMBLY
(22) Install plug in lockpin access hole.
(23) Install detent plunger, detent spring and
detent plug in case (Fig. 82).
FRONT OUTPUT SHAFT AND DRIVE CHAIN INSTALLATION
(1) Install front output shaft (Fig. 83).
(2) Install drive chain (Fig. 83). Engage chain with
front output shaft sprocket teeth.
(3) Install drive sprocket (Fig. 83). Engage drive
sprocket teeth with chain. Then engage sprocket
splines with mainshaft splines.
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