NVG 126-NP4

Transfer Case Motor/Encoder Replacement
Removal Procedure
1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the fuel tank shield, if equipped.





3. Disconnect the motor/encoder electrical connector (1).





4. Remove the motor/encoder mounting bolts.





5. Remove the motor/encoder assembly.

6. Important: When replacing the encoder rotary position sensor follow steps (6-10). The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder baseplate/gasket. The rotary position sensor replacement kit consists of a rotary position sensor, baseplate/gasket, and detailed instruction sheet.

Position the motor on a work bench.





7. Release the 4 tabs that retain the motor/encoder plastic baseplate and remove the baseplate/gasket (1).
8. Discard the old baseplate/gasket, replacement baseplate/gasket provided in rotary position sensor kit.

9. Important: The motor/encoder rotary position sensor internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed.

Gently lift the motor/encoder rotary position sensor (2) from the motor shaft.
10. Disconnect the rotary position sensor (2) from the wiring harness.

Important: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed.

Installation Procedure

1. Important: Provided the rotary position sensor was removed, follow steps (1-5) to install the sensor, otherwise proceed to step 6 installing the motor/encoder to the transfer case.

Connect the wiring harness to the rotary position sensor.
2. Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to insure the connector is fully installed.





3. Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic.





4. Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3).
5. Install the motor/encoder baseplate/gasket (1).





6. Important: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation.

Install the motor/encoder to the transfer case.





7. Notice: Refer to Fastener in Service Precautions.

Install motor/encoder mounting bolts to the transfer case.
Tighten the bolts to 16 Nm (12 ft. lbs.).





8. Connect the motor/encoder electrical connector (1).
9. Install the fuel tank shield, if equipped.
10. Lower the vehicle. Refer to Vehicle Lifting.