Jeep 1996 Grand Cherokee Service Manual - page 1321
(33) Remove magnet from case.
TRANSFER CASE ASSEMBLE
Lubricate the transfer case components with the
Mopar Dexron II during assembly operations.
Use petroleum jelly to lubricate and hold main-
shaft needle roller bearings and spacers in place.
Petroleum jelly can also be used to lubricate seals,
bushings and bearings during assembly.
Gaskets are not used in the NV249 transfer case.
Instead, the mating surfaces of the case halves,
retainer and extension are sealed with Mopar Gasket
Maker, silicone adhesive/sealer, or Loctite 518.
(1) Support front case on wood blocks. Position
case so sector shaft bore and input gear bearing are
accessible.
(2) Lubricate sector shaft, O-ring and shaft bore
(in case) with petroleum jelly.
(3) Install sector in case (Fig. 46).
(4) Lubricate shift rail bushing with light coat of
petroleum jelly, or transmission fluid. Do not over
lubricate bushing. Excess lubricant will flow
into bottom of bushing bore and prevent shift
rail from fully seating; this can also make it dif-
ficult to seat rear case on front case.
(5) Lubricate bearings and seals in front case with
transmission fluid or petroleum jelly.
(6) Install magnet in case.
(7) Align and install low range-input gear assem-
bly in front case (Fig. 47). Be sure low range gear
pinions are engaged in annulus gear and that input
gear shaft is fully seated in front bearing.
(8) Install snap-ring to hold input/low range gear
into front bearing (Fig. 48).
(9) Install new pads on range fork (Fig. 49).
(10) Lubricate range fork pads with light coat of
petroleum jelly.
(11) Install clutch sleeve in range fork (Fig. 49).
(12) Install assembled range fork and clutch sleeve
(Fig. 50). Insert range fork pin in sector. Then rotate
sector and seat clutch gear in low range gear.
Fig. 43 Input Gear Snap Ring Removal
Fig. 44 Input And Low Range Gear Assembly
Removal
Fig. 45 Range Lever Removal
Fig. 46 Shift Sector Removal
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TRANSMISSION AND TRANSFER CASE
ZJ
DISASSEMBLY AND ASSEMBLY (Continued)