Transfer case removal

ERINRITHER

MEMBER
2001 JEEP GRAND CHEROKEE
4.0L
6 CYL
4WD
AUTOMATIC
120,000 MILES

I have an 2001 Jeep Grand Cherokee WJ with a 242 transfer case and I need to get it out in order to remove the transmission. I have everything disconnected and all six bolts are off, but when I wiggle the tc to slide it off it will not budge.

Tuesday, March 15th, 2016 AT 1:23 PM

2 Replies

KEN L

MASTER CERTIFIED MECHANIC
47,640 POSTS

Hello,

It sounds like you have a spline caught, double check to make sure you have all 6 bolts out then wedge a breaker bar to lever the transfer case off the transmission output shaft.

Here is how the book says to remove the unit with a diagram below

Shift transfer case into NEUTRAL.
Raise vehicle.
Drain transfer case lubricant.
Mark front and rear propeller shaft yokes for alignment reference.
Support transmission with jack stand.

Remove rear crossmember, or skid plate.
Disconnect front/rear propeller shafts at transfer case.
Disconnect vehicle speed sensor wires.
Disconnect transfer case linkage rod from range lever.

Disconnect transfer case vent hose (Fig. 2) and indicator switch harness, if necessary.
Support transfer case with transmission jack.
Secure transfer case to jack with chains.
Remove nuts attaching transfer case to transmission.
Pull transfer case and jack rearward to disengage transfer case.
Remove transfer case from under vehicle.

INSTALLATION
Mount transfer case on a transmission jack.
Secure transfer case to jack with chains.
Position transfer case under vehicle.

Align transfer case and transmission shafts and install transfer case on transmission.
Install and tighten transfer case attaching nuts to 35 Nm (26 ft. Lbs.) Torque (Fig. 2).
Connect vehicle speed sensor wires, and vent hose.
Connect indicator switch harness to transfer case switch, if necessary. Secure wire harness to clips on transfer case.

Align and connect propeller shafts. Refer to Differential and Driveline for proper procedures and specifications.
Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.

Install rear crossmember, or skid plate. Tighten crossmember bolts to 41 Nm (30 ft. Lbs.) Torque.

Remove transmission jack and support stand.
Connect shift rod to transfer case range lever.
Adjust transfer case shift linkage.
Lower vehicle and verify transfer case shift operation.

Check out the diagrams (Below)

Let us know what happens and please upload pictures or videos of the problem.

Cheers, Ken

Image (Click to make bigger)