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.
^ For vehicles equipped with a one piece propeller shaft, refer to Propeller Shaft Replacement - One Piece.
^ For vehicles equipped with a two piece propeller shaft, refer to Propeller Shaft Replacement - Two Piece.
5. Remove the front propeller shaft from the transfer case. Refer to Propeller Shaft Replacement Front.





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 crossmember.
11. Install a suitable transmission jack to the transfer case.
12. Remove the bolts from the transfer case to the adapter.





Important: When performing this service procedure, pull straight back on the transfer case so that it is in a position so that it can be turn to a parallel to the transmission.

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





16. Remove the gasket from the transfer case.
17. Remove 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, make sure that the locating tab is pointing up for proper installation. Install the gasket without the use of any type of sealant or grease.

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





5. Rotate the transfer case so that it is in line 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 (36 ft. lbs.).





8. Install the transmission support member.
^ Tighten the crossmember mounting bolts to 70 Nm (51 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.
^ For vehicle equipped with a one piece propeller shaft, refer to Propeller Shaft Replacement One Piece.
^ For vehicles equipped with a two piece propeller shaft, refer to Propeller Shaft Replacement - Two Piece.
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.