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HOMESERVICE MANUALSJEEP1986CHEROKEE CHIEF, 4D UTILITY, 2.8 W, AUTOMATICREPAIR AND DIAGNOSIS (SINGLE PAGE)TRANSMISSIONTRANSFER CASETRANSFER CASE - OVERHAUL - NEW PROCESS 207 & 231TRANSFER CASE REASSEMBLY
1986 Jeep Cherokee Chief, 4D Utility, 2.8 W, Automatic

Transfer Case Reassembly

1986 Jeep Cherokee Chief, 4D Utility, 2.8 W, AutomaticSECTION Transfer Case Reassembly
NOTE: When installing bearings, ensure bearing bores are aligned with oil feed holes.
  1. Lubricate all parts with Dexron III before installing. Install output shaft front bearing with NEW snap ring. Install output shaft oil seal in front case. Install snap ring on NEW input gear bearing. See Figure or Figure .
  2. Press input gear bearing so snap ring is seated against case. Using press, install NEW input gear pilot bearing. Assemble low range gear, input gear, thrust washers and retainer.
  3. Install snap ring. Ensure snap ring is seated in low range gear groove. Start input gear shaft into bearing in front case. Press input shaft gear into bearing.
    CAUTION: DO NOT  press against end surfaces of gear. Failure to use proper size tool could lead to gear case or thrust washer damage.
  4. Install input gear snap ring. Install oil seal in front bearing retainer. Apply a 1/8" bead of silicone sealant to retainer mating surface. Align oil channel in retainer with oil feed hole in case. Install retainer on case. Tighten bolts to specification.
  5. Install sector shaft "O" ring and bushing. Install range sector in case. Install range lever and nut. Install detent, detent spring and plug. Tighten to specification. See TORQUE SPECIFICATIONS . Install NEW pads and fork rail bushings on range fork. Install range fork and shift hub.
  6. Ensure range fork pin is engaged with range sector slot. Press front bearing in drive sprocket until bearing is flush with bore edge. Install rear bearing until bearing is 3/16" below bore edge. See Fig 1.
  7. Install inserts and spring in synchronizer hub. Install sprocket on mainshaft. Install synchronizer stop ring on mainshaft. Ensure stop ring is seated. Install synchronizer hub on mainshaft. Align and seat hub inserts on stop ring lugs. Install synchronizer hub snap ring.
  8. Install synchronizer sleeve on hub. Ensure sleeve is positioned so beveled spline ends are facing stop ring. Ensure sleeve tooth is aligned (centered) over each synchronizer strut. Gear clash will occur if strut and sleeve teeth are misaligned. Install NEW pads on mode fork. Engage mode fork in synchronizer sleeve. Install mainshaft and fork assembly in case. Ensure mode fork shift rail is seated in both range fork bushings.
  9. Install output shaft and drive chain assembly. Install mode spring on shift rail. Using bearing driver, install output shaft rear bearing. Lubricate bearing after installation. Install seal in oil pump feed housing. Install oil pump in housing. Tighten to specification.
  10. Install oil pick-up tube "O" ring in oil pump. Prime oil pump by pouring ATF into pump through pick-up tube opening. Install oil pump and pick-up tube in case. Ensure oil screen is properly positioned. See Fig 2. Install magnet in front case. Apply 1/8" bead of silicone sealer to front case. Install rear case. Tighten to specification. See TORQUE SPECIFICATIONS . Ensure mainshaft splines are engaged with oil pump inner gear and a washer is used on bolts at dowel locations.
  11. Install rear bearings in retainer. Apply 1/8" bead of silicone sealer and install retainer to case. Install rear retainer snap ring. Install extension housing. Install front companion yoke. Install NEW gasket on vacuum switch. Install vacuum switch in case. Fill transfer case with Dexron III.
Fig 1: Installing Drive Sprocket Bearings
G92G13082Courtesy of CHRYSLER CORP.
RENDER: 1.0x

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.