Transfer Case-Mechanical Shift
Transfer Case-Mechanical ShiftFor Integrated Wheel End (IWE) vacuum disconnect procedures, refer to Drive Axles, Bearings and Joints/Axle Shaft Assembly/Front Axle Halfshafts. Front Drive Halfshaft
Material
1. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.
Remove the front driveshaft.
2. NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft.
Remove the rear driveshaft.
3. Remove the skid plate, if equipped.
^ To install, tighten to 18 Nm (13 ft. lbs.).
4. Drain the fluid if the transfer case is to be disassembled.
5. Disconnect the transfer case wire harness
6. NOTE: The transfer case shift linkage assembly is serviced as an assembly only. If any part is damaged or worn, install a new assembly.
Using a 5/8-inch wrench, disconnect the shift linkage from the shift bracket.
7. Disconnect the vent tube.
8. CAUTION: Secure the transfer case to the jack with a safety strap.
Using a suitable jack, support the transfer case. Securely strap the transfer case to the jack.
9. Remove the transfer case.
^ Remove the 6 transfer case-to-transmission bolts and separate the transfer case from the transmission.
^ To install, tighten to 47 Nm (35 ft. lbs.).
^ Tighten the transmission-to-transfer case bolts evenly in a star pattern.
^ Separate the transfer case from the transmission.
10. Lower the transfer case from the vehicle.
11. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.
Remove the transfer case-to-transmission gasket and clean the mating surfaces.