Cherokee, Grand Cherokee, 1999-2005

Transfer Case Removal & Installation

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NV140



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise vehicle.
  4.  
  5. Remove transfer case drain plug and drain the transfer case lubricant.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  6.  
  7. Remove the front and rear propeller shafts.
  8.  
  9. Support transmission with jack stand.
  10.  
  11. Remove rear crossmember and skid plate, if equipped.
  12.  
  13. Disconnect transfer case vent hose.
  14.  
  15. Support transfer case with transmission jack and secure with chains.
  16.  
  17. Remove nuts attaching transfer case to transmission.
  18.  
  19. Pull transfer case and jack rearward to disengage transfer case.
  20.  
  21. Remove transfer case from under vehicle.
  22.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case onto the transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs.(35 Nm).
  10.  
  11. Connect front and rear drive shafts. Torque the front driveshaft-to-transfer case bolts to 24 ft. lbs. (32 Nm). Torque the rear driveshaft-to-transfer case bolts to 80 ft. lbs. (108 Nm).
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install the transfer case fill plug. Tighten the plug to 15-25 ft. lbs. (20-34 Nm).
  16.  
  17. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs.(41 Nm).
  18.  
  19. Remove transmission jack and support stand.
  20.  
  21. Lower vehicle and verify transfer case shift operation.
  22.  

Nv147



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Raise vehicle.
  4.  
  5. Remove transfer case drain plug and drain transfer case lubricant.
  6.  
  7. Mark front and rear propeller shaft yokes for alignment reference.
  8.  
  9. Support transmission with jack stand.
  10.  
  11. Remove rear crossmember and skid plate, if equipped.
  12.  
  13. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  14.  
  15. Disconnect transfer case vent hose.
  16.  
  17. Support transfer case with transmission jack.
  18.  
  19. Secure transfer case to jack with chains.
  20.  
  21. Remove nuts attaching transfer case to transmission.
  22.  
  23. Pull transfer case and jack rearward to disengage transfer case.
  24.  
  25. Remove transfer case from under vehicle.
  26.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. 35 Nm).
  10.  
  11. Connect front propeller shaft and install rear propeller shaft.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Lower vehicle and verify transfer case shift operation.
  20.  

Nv231 & Nv242



  1. Shift transfer case into Neutral.
  2.  
  3. Raise vehicle.
  4.  
  5. Drain transfer case lubricant.
  6.  
  7. Mark front and rear propeller shaft yokes for alignment reference.
  8.  
  9. Support transmission with jack stand.
  10.  
  11. Remove rear crossmember, or skid plate.
  12.  
  13. Disconnect front/rear propeller shafts at transfer case.
  14.  
  15. Disconnect vehicle speed sensor wires.
  16.  
  17. Disconnect transfer case linkage rod from range lever.
  18.  
  19. Disconnect transfer case vent hose and indicator switch harness, if necessary.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle
  30.  

To install:

Click image to see an enlarged view

Fig. NV242 and NV231 transfer case mounting points

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm)
  10.  
  11. Connect vehicle speed sensor wires, and vent hose.
  12.  
  13. Connect indicator switch harness to transfer case switch, if necessary. Secure wire harness to clips on transfer case.
  14.  
  15. Align and connect propeller shafts.
  16.  
  17. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  18.  
  19. Install rear crossmember or skid plate. Tighten crossmember bolts to 30 ft. lbs.41 Nm).
  20.  
  21. Remove transmission jack and support stand.
  22.  
  23. Connect shift rod to transfer case range lever.
  24.  
  25. Adjust transfer case shift linkage.
  26.  
  27. Lower vehicle and verify transfer case shift operation.
  28.  

NV242



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove transfer case drain plug and drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shaft yokes for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove rear crossmember and skid plate, if equipped.
  14.  
  15. Disconnect front/rear propeller shafts at transfer case.
  16.  
  17. Disconnect transfer case cable from range lever.
  18.  
  19. Disconnect transfer case vent hose and transfer case position sensor.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

Click image to see an enlarged view

Fig. NV242 transfer case mounting points

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm).
  10.  
  11. Align and connect propeller shafts.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Connect shift rod to transfer case range lever.
  20.  
  21. Connect transfer case vent hose and transfer case position sensor.
  22.  
  23. Adjust transfer case shift cable.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

NV245



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove transfer case drain plug and drain transfer case lubricant.
  8.  
  9. Support transmission with jack stand.
  10.  
  11. Remove rear crossmember and skid plate, if equipped.
  12.  
  13. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  14.  
  15. Disconnect the transfer case shift motor and mode sensor connector.
  16.  
  17. Disconnect transfer case vent hose.
  18.  
  19. Support transfer case with transmission jack.
  20.  
  21. Secure transfer case to jack with chains.
  22.  
  23. Remove nuts attaching transfer case to transmission.
  24.  
  25. Pull transfer case and jack rearward to disengage transfer case.
  26.  
  27. Remove transfer case from under vehicle.
  28.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case onto transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs.(35 Nm).
  10.  
  11. Connect the transfer case vent hose to the transfer case.
  12.  
  13. Install rear crossmember and skid plate, if equipped.
  14.  
  15. Remove transmission jack and support stand.
  16.  
  17. Connect front and rear drive shafts. Torque the front driveshaft-to-transfer case bolts to 24 ft. lbs. (32 Nm). Torque the rear driveshaft-to-transfer case bolts to 80 ft. lbs. (108 Nm).
  18.  
  19. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  20.  
  21. Install the transfer case fill plug. Tighten the plug to 15-25 ft. lbs. (20-34 Nm).
  22.  
  23. Connect the shift motor and mode sensor wiring connector.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

Nv247



  1. Before servicing the vehicle, please familiarize yourself with safety procedures.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove transfer case drain plug and drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shaft yokes for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove rear crossmember and skid plate, if equipped.
  14.  
  15. Disconnect front propeller shaft from transfer case at companion flange. Remove rear propeller shaft from vehicle.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  16.  
  17. Disconnect transfer case cable from range lever.
  18.  
  19. Disconnect transfer case vent hose.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

Click image to see an enlarged view

Fig. NV247 transfer case mounting points

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm).
  10.  
  11. Connect front propeller shaft and install rear propeller shaft.
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 nm).
  16.  
  17. Remove transmission jack and support stand.
  18.  
  19. Verify transfer case is in NEUTRAL. Connect shift cable to transfer case range lever.
  20.  
  21. Lower vehicle and verify transfer case shift operation.
  22.  
  23. Adjust the transfer case shift cable, if necessary.
  24.  

 
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