Transfer Case Replacement (With Automatic Transmission)
REMOVAL PROCEDURE1. Raise and support the vehicle.
2. Remove the transfer case shield.
3. Remove the front and rear propeller shafts.
4. Remove the vent hose from the transfer case vent.
5. Disconnect the electrical connectors from the three speed sensors.
6. Disconnect the electrical connector from the encoder/motor.
7. Remove the wiring harness from the transfer case.
8. Support the transfer case with a jack.
9. Remove the bolts securing the transfer case to the transmission.
10. Remove the transfer case from the transmission.
11. Remove and discard the gasket.
INSTALLATION PROCEDURE
1. Install a new gasket to the transmission. Apply a thin coat of clear RTV in order to hold the gasket in place.
2. Install the transfer case to the transmission.
3. Install the bolts that secure the transfer case to the transmission.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
NOTICE: Refer to Fastener Notice in Service Precautions.
4. Remove the jack from the transfer case.
5. Connect the electrical connector to the three speed sensors.
6. Connect the electrical connector to the encoder/motor.
7. Install the vent hose to the transfer case vent.
8. Install the front and rear propeller shafts.
9. Install the transfer case shield.
^ Check the transfer case oil level. Add oil as necessary.
^ Lower the vehicle.
10. Check the transfer case for normal operation.