Transfer Case: Service and Repair

REMOVAL
1. Raise and support vehicle.
2. Drain transfer case lubricant into suitable container.
3. Scribe reference marks between front and rear transfer case output shaft yokes and driveshafts.
4. Disconnect speedometer cable and vacuum switch hoses.
5. Disconnect transfer case shift lever linkage from gearshift assembly.
6. Support transmission with suitable jack, then remove rear crossmember.
7. Remove driveshafts from front and rear transfer case output shaft yokes, then wire driveshafts to frame. Do not allow driveshafts to hang from axle flanges.
8. If necessary, remove exhaust pipe support bracket attaching bolts from transfer case.
9. Remove transfer case to transmission attaching nuts, then pull transfer case rearward until clear of transmission output shaft.
10. Remove transfer case from vehicle. Remove all gasket material from transmission adapter housing.

INSTALLATION
1. Apply Permatex No. 3 sealer, or equivalent, to both sides of transfer case to transmission gasket, then position gasket on transmission.
2. Install transfer case assembly on transmission. Ensure transfer case input shaft splines are aligned with transmission output shaft splines. If necessary, rotate transfer case rear output shaft flange to align splines. Do not install any attaching nuts until transfer case mounting surface is completely seated against transmission mounting surface.
3. Install transfer case attaching nuts. Torque attaching nuts to 35 ft. lbs.
4. Install transmission rear crossmember, then remove jack from transmission.
5. If removed, install exhaust pipe support bracket attaching bolts.
6. Install driveshafts. Align reference marks prior to installation.
7. Connect speedometer cable and vacuum switch hoses.
8. Connect shift linkage to gearshift assembly. Torque attaching locknut to 18 ft. lbs.
9. Fill transfer case with suitable fluid.
10. Lower vehicle.