Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield from the crossmember.
3. Remove the brace from the transfer case left side shown, if equipped.
4. Drain the transfer case of fluid.
5. Remove the rear propeller shaft from the vehicle.
6. Remove the front propeller shaft from the vehicle.





7. Remove the motor/encoder electrical connector.





8. Remove the electrical wiring harness from the transfer case.





9. Remove the vent hose from the transfer case.
10. Support the transmission with a suitable jack stand.





11. Remove the transmission mount retaining bolts from the transmission support.





12. Remove the transmission support mounting bolts from the frame.
13. Remove the transmission support assembly.





14. Remove the transmission mount from the transfer case adapter (automatic transmission only).





15. Remove the transfer case to the transfer case adapter retaining nuts.

16. Important: This service procedure should be performed with the aid of another technician.

Remove the transfer case from the transfer case adapter straight back toward the rear of the vehicle.
17. Lower the front of the transfer case.
18. Raise the rear of the transfer case so that it above the torsion bar bracket.
19. In a downward motion, remove the transfer case from the vehicle.





20. Important: If during the removal of the transfer case the gasket becomes damaged, do not reuse the gasket. Replace the damaged gasket with a new one. DO NOT use any type of sealant in place of the gasket.

Remove the transfer case gasket.

Installation Procedure





1. Install the new gasket to the transfer case adapter with the tab facing upward.

2. Important: This service procedure should be performed with the aid of another technician.

Install the transfer case to the transfer case adapter.





3. Notice: Refer to Fastener Notice in Service Precautions.

Install the transfer case retaining nuts on the transfer case mounting studs.
^ Tighten the transfer case retaining nuts to 55 Nm (40 ft. lbs.).





4. Install the transmission mount to the transfer case adapter.
^ Tighten the transmission mount bolts to 47 Nm (35 ft. lbs.).





5. Install the transmission support assembly.





6. Install the transmission mount retaining nuts.
^ Tighten the transmission mount retaining nuts and bolts to 40 Nm (30 ft. lbs.).
7. Remove the transmission jack from the transmission.





8. Install the motor/encoder electrical connector.





9. Install the electrical wiring harness to the transfer case.





10. Install the vent hose to the transfer case.





11. Install the transfer case brace left side shown, if equipped.
12. Install the transfer case brace bolts at the transfer case.
^ Tighten the transfer case to engine bolts to 60 Nm (44 ft. lbs.).
13. Install the transfer case brace bolt at the engine.
^ Tighten the transfer case brace bolt to 47 Nm (35 ft. lbs.).
14. Install the rear propeller shaft in the vehicle.
15. Install the front propeller shaft in the vehicle.
16. Fill the transfer case with the approved fluid.
17. Install the transfer case shield to the vehicle.
18. Lower the vehicle. Refer to Vehicle Lifting.