Transfer Case Shifter - Thumping/Creaking Noise

NO: 21-02-97 Rev.A

GROUP: Transmission

DATE: Jul. 11, 1997

SUBJECT:
Transfer Case Shifter Noise

THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN NUMBER 21-02-97, DATED, MARCH 7, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILE. THE BULLETIN REVISES THE SYMPTOM/CONDITION TO INCLUDE A CREAKING NOISE. THE CHANGE IS HIGHLIGHTED WITH **ASTERISKS**.

MODELS:
1993 - 1997 (ZJ) Grand Cherokee/Grand Wagoneer
1994 - 1997 (ZG) Grand Cherokee (International Market)

SYMPTOM/CONDITION:

**A thumping or creaking noise may be heard coming from the transmission tunnel area on acceleration or while driving over bumpy roads.**

DIAGNOSIS:

Road test the vehicle, if the noise is present and there are no worn or damaged parts relating to the transfer case shift mechanism, perform the Repair Procedure.

PARTS REQUIRED:

1     04886481AA       Repair Kit, Transfer Case Shifter

REPAIR PROCEDURE:

This bulletin involves installing a transfer case shifter repair kit.

1. Disconnect the shift rods from the torque shaft.

2. Remove the torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket. (Refer to Figure 1)

3. Remove the bronze bushing/retainer and rubber gasket from the body bracket.

4. Remove the green torque shaft bushing from the transmission bracket and install the new bushing supplied in the kit.

4. Insert the new gasket into the body bracket.

5. Install the bronze bushing/retainer and tightening the screws to 5 Nm (45 in. lbs.).

6. Slide the boot on to the torque shaft and apply multipurpose grease (MOPAR p/n 04318063 or equivalent) to the area that the bronze bushing will contact.

7. Install the torque shaft and seat the boot on the bushing retainer flange.

8. Connect the transfer case shift linkage and adjust as necessary.

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:
Labor Operation No: 21-03-10-90                           0.6 Hrs.

FAILURE CODE:       P8 - New Part