Installation

Transfer Case

All vehicles
1. Install a new mounting gasket.





2. CAUTION: Secure the transfer case to the high-lift jack with a safety strap.

Raise the transfer case into position.





3. Install the 6 transfer case-to-transmission bolts.
^ Tighten to 50 Nm (37 ft. lbs.).





Automatic transmission vehicles
4. Remove the jack stand from the extension housing.





5. Install the transmission mount.
^ Tighten to 95 Nm (70 ft. lbs.).





6. Position the crossmember and loosely install the 2 transmission mount nuts.





7. Install the 3 LH crossmember nuts.
^ Tighten to 70 Nm (52 ft. lbs.).





8. Install the RH crossmember nuts.
^ Tighten to 70 Nm (52 ft. lbs.).





All vehicles
9. Remove the high-lift jack. Automatic transmission vehicles





10. Tighten the transmission mount-to-crossmember nuts.
^ Tighten to 94 Nm (69 ft. lbs.).





All electric shift transfer cases
11. Connect the vent hose.





12. Connect the 2 gear motor encoder assembly electrical connectors.








All manual shift transfer cases
13. Connect the 3-position mode switch harness connector.





14. Connect the manual shift linkage. All vehicles

15. CAUTION: Align the index-marks when installing the driveshaft.

Connect the front driveshaft to the transfer case and install the 4 new front driveshaft flange bolts.
^ Tighten to 111 Nm (82 ft. lbs.).





16. Install the rear driveshaft.
17. If equipped, install the skid plate and the 4 bolts.
^ Tighten to 24 Nm (18 ft. lbs.).





18. If drained, fill the transfer case.