Jeep Wagoneer/Commando/Cherokee 1984-1998

Transfer Case Assembly

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Removal & Installation



See Figures 1 and 2



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Fig. Fig. 1: Disconnect the speedometer cable ...



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Fig. Fig. 2: ... and any electrical connections from the transfer case

  1. Shift transfer case into N .
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Drain the lubricant.
  6.  
  7. Matchmark and remove the front and rear driveshafts.
  8.  
  9. Raise and support the transmission with a floor jack.
  10.  
  11. Remove the rear crossmember.
  12.  
  13. Disconnect the speedometer cable.
  14.  
  15. Disconnect the linkage.
  16.  
  17. Disconnect the vent and vacuum hoses and the indicator wire.
  18.  
  19. Support the transfer case with a transmission jack. Make sure that the case is secured to the jack with chains.
  20.  
  21. Remove the transfer case-to-transmission bolts.
  22.  
  23. Pull the case rearward to disengage it and lower it from the truck.
  24.  

To install:
  1. Raise the transfer case into position. Tighten the bolts to 26 ft. lbs. (35 Nm).
  2.  

Make certain that the case and transmission are mated without binding, before torquing the attaching bolts.

  1. Connect the shift linkage at the case.
  2.  
  3. Connect the vacuum hoses.
  4.  
  5. Install the driveshafts.
  6.  
  7. Install the rear crossmember. Tighten the crossmember-to-frame bolts to 30 ft. lbs. (41 Nm); the transmission-to-crossmember bolts to 33 ft. lbs. (45 Nm).
  8.  
  9. Remove the transmission floor jack.
  10.  
  11. Connect the speedometer cable and vent hose.
  12.  
  13. Connect the shift lever link at the operating lever.
  14.  
  15. Fill the case with lubricant. Lower the vehicle.
  16.  

ADJUSTMENTS



Range Control Linkage
NP-207 MODELS

See Figure 3

  1. Place the range control lever in the 2WD position.
  2.  
  3. Insert a 1 / 8 in. (3mm) spacer between the gate and the lever.
  4.  
  5. Hold the lever in this position.
  6.  



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Fig. Fig. 3: NP-207 range control adjustment point (A)

  1. Place the transfer case lever in the 2WD position.
  2.  
  3. Adjust the link, at the trunnion, to provide a free pin at the case outer lever.
  4.  

NP-228 AND 229 MODELS

See Figure 4

  1. Place the range control lever in the HIGH position.
  2.  
  3. Insert a 1 / 8 in. (3mm) spacer between the shift gate and the lever.
  4.  



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Fig. Fig. 4: NP-228/229 range control adjustment point (B)

  1. Hold the lever in this position with tape.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Verify that the range lever is in the HIGH position.
  6.  
  7. Loosen the locknut and adjust the link, at the trunnion, to provide a free pin at the case outer lever. Tighten the locknut.
  8.  
  9. Lower the vehicle. Remove the spacer.
  10.  

231 AND 242 MODELS

See Figure 5

  1. Remove the shifter lever bezel.
  2.  
  3. Place the range control lever in the 4 LOW position.
  4.  
  5. Insert a 1 / 8 in. (4mm) spacer between the forward edge of the shift gate and the lever.
  6.  



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Fig. Fig. 5: Range control adjustment on the 231/242

  1. Hold the lever in this position with tape.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Loosen the trunnion lock bolt. The linkage rod should now slide freely in the trunnion.
  6.  
  7. Position the linkage rod so it is free in the range lever. Then tighten the locknut.
  8.  
  9. Lower the vehicle. Remove the spacer.
  10.  

NV/NP-249 MODELS
  1. Place the range control lever in the N position.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Loosen the trunnion lockbolt. The linkage rod should now slide freely in the trunnion.
  6.  
  7. Verify the shift lever on the transfer case is centered in the N position.
  8.  
  9. Tighten the lockbolt to 96-180 inch lbs. (11-20 Nm).
  10.  
  11. Lower the vehicle. Remove the spacer.
  12.  

Mode Rod
NP-228 AND NP-229 MODELS

See Figure 6


WARNING
If this adjustment is not properly made, the transfer case may not fully engage 2WD/HIGH and internal damage will result.

  1. Fully engage the 2WD/HIGH position.
  2.  
  3. Refer to the accompanying illustration. The range lever and the mode lever must be aligned on the same centerline.
  4.  



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Fig. Fig. 6: Mode rod adjustment components

To correctly position the mode lever, it is sometimes necessary to rotate the transfer case output shaft. To do this, raise and support the rear end on jackstands and rotate the rear driveshaft, while applying a load on the mode lever. Doing this will help align the spline for full engagement of 2WD/HIGH.

  1. Adjust the length of the mode rod (4) to approximately 6 in. (152mm), to eliminate all free play.
  2.  
  3. Make sure all vacuum lines are secure.
  4.  
  5. Drive the vehicle a short distance, shifting between 4WD and 2WD/HIGH .
  6.  
  7. Check the mode lever position. The lever should be aligned as explained in Step 2. If not, repeat Steps 3 through 5, increasing the length of the mode rod one turn, until proper alignment is achieved.
  8.  
  9. With the transfer case vacuum motor shift rod fully extended and the transfer case in 2WD/HIGH , adjust the mode rod so that the pin (6) moves freely in its hole.
  10.  

 
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