125. Transfer Case Installation (F4WD Only)

Transfer Case Installation (F4WD Only)

^ Tools Required
- J 36850 TRANJEL Lubricant (or equivalent)





1. Install the case extension seal (8) using J 36850 in order to retain.





Notice: The oil dam must be installed with the oil passage notch aligned to the passage in the case. Incorrect alignment will cause oil flow stoppage and damage to the transmission.

2. Line up the notch (1) to the hole in the case and install the oil dam (901).





3. Install the transfer case lower brace (906).
4. Install the transfer case lower brace bolts (903). Hand tighten.





Caution: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

5. Rotate the transaxle so that the bottom pan is facing the floor.
6. Install the transfer case assembly (908) onto the transmission case (3).





7. Install the five transfer case to case bolts (907, 909, 910).





8. Torque the bolts in the following sequence:

Notice: Refer to Fastener Notice in Service Precautions.

9. Tighten two transfer case bolts (1, 2):
^ First pass 35 Nm (26 ft. lbs.).
^ Final Pass an additional 160°.
10. Tighten one transfer case bolt (3):
^ First pass 35 Nm (26 ft. lbs.).
^ Final Pass an additional 70°.
11. Tighten two transfer case bolts (4, 5):
^ Tighten transfer case bolts (4, 5) to 40 Nm (30 ft. lbs.).





12. Install the transfer case side brace (905) to case.
13. Install the transfer case side brace to case bolts (903). Hand Tighten bolts.
14. Torque bolts in the following sequence, (1, 2, 3, 4, 5).
^ Tighten transfer case side brace bolts to 31 Nm (23 ft. lbs.).





15. Install the transfer case lower brace to case bolt (904).
^ Tighten transfer case lower brace bolt to 56 Nm (42 ft. lbs.).





16. Tighten the transfer case lower brace to case bolts (903).
^ Tighten transfer case lower brace bolts to 31 Nm (23 ft. lbs.).