Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield, if equipped.
3. Drain the transfer case.
4. Remove the rear propeller shaft from the transfer case.
5. Remove the front propeller shaft from the transfer case.





6. Remove the vent hose from the transfer case.





7. Remove the electrical connector from the speed sensor.
8. Support the transmission with a suitable jack stand.





9. Remove the transmission mount from the crossmember.





10. Remove the rear transmission cross member.
11. Install a suitable transmission jack to the transfer case.
12. Remove the bolts from the transfer case to the adapter.





Important: Pull straight back on the transfer case, in order to position the transfer case so that the transfer case can be turned parallel to the transmission.

13. Remove the transfer case from the transfer case adapter.
14. Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
15. Lower the transfer case.





16. Remove the gasket from the transfer case.
17. Remove the transfer case from the transmission jack.

Installation Procedure





1. Install the transfer case on a suitable transmission jack.

Important: When installing a new transfer case gasket, ensure that the locator tab is facing up for proper installation. Install the gasket without the use of any type of sealant or of lubricant.

2. Install a new transfer case gasket.
3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
4. Raise the transfer case into position.





5. Rotate the transfer case so that the transfer case is aligned with the adapter.
6. Install the transfer case on the adapter.





Notice: Refer to Fastener Notice in Service Precautions.

7. Install the mounting nuts for the transfer case.
^ Tighten the mounting nuts to 50 Nm (37 ft. lbs.).





8. Install the transmission support member.
^ Tighten the cross member mounting bolts to 70 Nm (50 ft. lbs.).





9. Install the transmission mount to the transfer case.
10. Remove the transmission jack.
11. Install the electrical connector to the speed sensor.





12. Install the vent hose to the vent tube.
13. Install the front propeller shaft.
14. Install the rear propeller shaft.
15. Fill the transfer case with the proper transfer case fluid.





16. Install the transfer case shield.
17. Lower the vehicle. Refer to Vehicle Lifting.