Jeep Cherokee 2000 Service Manual - page 1688
(3) Remove seal washer from front output shaft.
Discard washer as it should not be reused.
(4) Remove nut and washer that attach range
lever to sector shaft. Then move sector to neutral
position and remove range lever from shaft (Fig. 22).
FRONT OUTPUT SHAFT AND DRIVE CHAIN REMOVAL
(1) Remove drive sprocket snap-ring (Fig. 23).
(2) Remove drive sprocket and chain (Fig. 24).
(3) Remove front output shaft (Fig. 25).
SHIFT FORKS AND MAINSHAFT REMOVAL AND
DISASSEMBLY
(1) Remove shift detent plug, spring and pin (Fig.
26).
(2) Remove seal plug from low range fork lockpin
access hole. Then move shift sector to align low range
fork lockpin with access hole.
(3) Remove range fork lockpin with size number
one easy-out tool as follows:
(a) Insert easy-out tool through access hole in
side of transfer case and into lock-pin.
(b) Tap easy-out tool into lock-pin with hammer
until tool is securely engaged into the lock-pin.
Fig. 21 Yoke Removal
1 – PULLER TOOL
2 – YOKE
Fig. 22 Range Lever Removal
1 – RANGE LEVER
2 – SECTOR SHAFT
Fig. 23 Drive Sprocket Snap-Ring Removal
1 – DRIVE SPROCKET
2 – DRIVE SPROCKET SNAP RING
Fig. 24 Drive Sprocket And Chain Removal
1 – DRIVE SPROCKET
2 – DRIVE CHAIN
XJ
NV242 TRANSFER CASE
21 - 383
DISASSEMBLY AND ASSEMBLY (Continued)