Transfer Case: Service and Repair

Fig. 1 Shifter & shift lever mounting:

REMOVAL

1. Position transfer case shift lever at 4 Hi.
2. Disconnect battery ground cable.
3. Raise and support vehicle and remove skid plate, then drain transfer case.
4. Scribe reference marks on transfer case front output shaft yoke and drive shaft, then disconnect front driveshaft from transfer case.
5. Scribe reference marks on rear axle yoke and driveshaft, then remove rear driveshaft.
6. Disconnect vacuum harness and speedometer cable from transfer case, then remove shift lever.
7. Remove catalytic converter hanger bolts, then raise transmission and transfer case assembly and remove transmission mount attaching bolts and the mount.
8. Remove catalytic converter hanger, then lower transmission and transfer case assembly.
9. Support transfer case with a suitable jack, then remove transfer case attaching bolts. On models equipped with automatic transmission, remove shift lever bracket mounting bolts, Fig. 1, to gain access to upper left side transfer case mounting bolt.
10. Remove transfer case.

Fig. 5 Transfer case installation:

INSTALLATION

1. Position new gasket on transfer case as shown in Fig. 5.
2. Position transfer case near end of transmission, then align transfer case input shaft splines with transmission splines and slide transfer case forward until seated against transmission.
3. Install transfer case attaching bolts. Torque bolts to 19-29 ft. lbs. On models equipped with automatic transmission, install shift lever bracket mounting bracket bolts.
4. Raise transmission and transfer case assembly with a suitable jack, then install mount and catalytic converter hanger bracket. Lower transmission and transfer case assembly.
5. Install transmission mount attaching bolts and torque to 23 ft. lbs.
6. Install and tighten catalytic converter hanger bolts at converter.
7. Install shift lever to transfer case, then connect vacuum harness and speedometer cable.
8. Install front and rear driveshafts. Ensure reference marks are aligned prior to assembly.
9. Fill transfer case with suitable lubricant.
10. Install skid plate, then lower vehicle.
11. Connect battery ground cable.
12. Road test vehicle. Ensure vehicle shifts and operates in all ranges.