Removal and Installation

TRANSFER CASE REMOVAL

1. Raise vehicle on hoist.

2. Remove transfer case skid plate, if equipped.

3. Mark front and rear propeller shafts and U-joints for installation reference. Then disconnect and remove both propeller shafts.

4. Disconnect distance sensor wires at transfer case and disconnect speedometer cable, if equipped.

5. Disconnect harness wires at transfer case switch.

6. Disconnect vent hose from tube on transfer case.

7. Disconnect transfer case shift linkage at range lever. Then remove linkage bracket bolts and remove linkage and bracket from transfer case. Move linkage aside for clearance.

8. Remove nuts attaching transfer case to transmission adapter housing.

9. Remove transfer case with aid of helper. Support transfer case with transmission jack. Move transfer case rearward, tilt it away from fixed rear crossmember and work it out from between transmission and crossmember.

TRANSFER CASE INSTALLATION

Transfer Case Mounting:

1. Install transfer case. Align and position transfer case with transmission jack or with aid of helper. Tilt case upward and work into position on transmission mounting studs.

2. Install and tighten transfer case attaching nuts to 47 Nm (35 ft. lbs.) torque.

3. Install and connect transfer case shift linkage.

4. Connect distance sensor wires. If vehicle is also equipped with speedometer cable, connect cable to sensor.

5. Align and install front and rear propeller shafts. Tighten U-joint clamp bolts to 19 Nm (170 in. lbs.) torque.

6. Connect wire harness to switch on transfer case.

Transfer Case Vent Hose Routing:

7. Connect vent hose to tube on transfer case.

8. Check transfer case fluid level. Add MOPAR ATF Plus, or Dexron II fluid if necessary. Correct level is to edge of fill plug hole. Be sure transfer case is level before checking or adding fluid.

9. Install transfer case skid plate, if equipped.

10. Lower vehicle.

11. Check and adjust transfer case shift linkage if necessary.