Nv242 Transfer Case Cleaning And Inspection - Jeep 200 Cherokee Service Manual

21 - 402 NV242 TRANSFER CASE
DISASSEMBLY AND ASSEMBLY (Continued)
Fig. 91 Slinger Boot Installation
1 – SPECIAL TOOL C-4975–A
2 – SLINGER
3 – BOOT
4 – CLAMP
Fig. 90 Rear Seal Installation
1 – SPECIAL TOOL C-4076–B
2 – SPECIAL TOOL MD998323
3 – TRANSFER CASE
CLEANING AND INSPECTION
NV242 TRANSFER CASE
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 all
purpose cleaner. Use compressed air to remove sol-
vent residue from oil feed passages in the case
halves, retainers, gears, and shafts.
The oil pickup screen can be cleaned with solvent.
Shake excess solvent from the screen after cleaning
and allow it to air dry. Do not use compressed air.
MAINSHAFT/SPROCKET/HUB INSPECTION
Inspect the splines on the hub and shaft and the
teeth on the sprocket. Minor nicks and scratches can
be smoothed with an oilstone. However, replace any
part 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 (Fig. 92). 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 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 and both thrust washers for
wear or cracks. Replace them if necessary. Also
replace the lock retaining ring if bent, distorted, or
broken.
SHIFT FORKS/HUBS/SLEEVES
Check condition of the shift forks and mode fork
shift rail (Fig. 93). Minor nicks on the shift rail can
be smoothed with 320–400 grit emery cloth.
Inspect the shift fork wear pads. The mode fork
pads are serviceable and can be replaced if necessary.
The range fork pads are also serviceable.
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/BEARING/ SEAL/SLINGER/BOOT
Inspect the retainer components (Fig. 94). Replace
the bearing if rough or noisy. Check the retainer for
cracks or wear in the bearing bore. Clean the
retainer sealing surfaces with a scraper and all pur-
pose cleaner. This will ensure proper adhesion of the
sealer during reassembly.
Replace the slinger and seal outright; do not reuse
either part.
Inspect the retaining rings and washers. Replace
any part if distorted, bent, or broken. Reuse is not
recommended. Also replace the boot if cut or torn.
Replace the boot band clamps, do not reuse them.
REAR OUTPUT SHAFT/YOKE/DRIVE CHAIN
Check condition of the seal contact surfaces of the
yoke slinger (Fig. 95). This surface must be clean and
smooth to ensure proper seal life. Replace the yoke
nut and seal washer as neither part should be
reused.
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