Transfer Case: Service and Repair

1. Raise and support vehicle, then remove front wheel and tire assemblies.
2. Remove propeller shaft as outlined under Propeller Shaft Replacement.
3. Remove crossmember attaching bridge bolts.
4. Remove power steering hose bracket, attaching screw.
5. Secure rack and pinion to frame rail using suitable wire or equivalent.
6. Remove lower ball joints.
7. Remove lower bobble strut bolt.
8. Using suitable transmission jack, support crossmember.
9. Remove front crossmember attaching bolts, then carefully lower crossmember.
10. Remove right front driveshaft, some oil will drain from transaxle when driveshaft is removed.
11. Remove PTU bracket and bobble strut assembly attaching bolts, then remove strut.
12. Remove rear PTU attaching brace bolts.
13. Remove distance sensor attaching bolt, then remove.
14. Remove remote PTU vent at left engine mount.
15. Remove four PTU attaching bolts, then remove unit.
16. Reverse procedure to install, noting the following:
a. Torque PTU to engine bracket M10 bolt to 30 ft. lbs. and M8 bolt to 220 inch lbs.
b. Torque propeller shaft to PTU assembly to 250 inch lbs.
c. Torque wheel lug nuts to 95 ft. lbs.