Transfer Case Replacement (With Manual Transmission)

REMOVAL PROCEDURE





1. Raise and support the vehicle.
2. Remove the transfer case shield.
3. Remove the front and rear propeller shafts.
4. Remove the bolts and stud securing the left side transfer case support to the transfer case and transmission.





5. Remove the bolts securing the right side transfer case support to the transfer case and transmission.





6. Remove the vent hose from the transfer case.
7. Disconnect the electrical connector from the vehicle speed sensor.
8. Disconnect the electrical connector from the Encoder/Motor.
9. Remove the wiring harness from the transfer case.
10. Support the transfer case with a jack.





11. Remove the transfer case from the adaptor using the following procedure:
^ Remove the bolts securing the transfer case to the adapter.
^ Slide and twist the transfer case back from the transmission.
^ Lower the transfer case.





12. Remove and discard the adaptor to the transfer case gasket.

INSTALLATION PROCEDURE





1. Install a new gasket to the transmission, Use a gasket sealer in order to hold the gasket in place.





2. Install the transfer case to the transmission adapter.
3. Install the bolts that secure the transfer case to the transmission adapter.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).

NOTICE: Refer to Fastener Notice in Service Precautions.





4. Install the bolts and stud securing the left side transfer case support to the transfer case and transmission.





5. Install the bolts securing the right side transfer case support to the transfer case and transmission.
6. Remove the jack from the transfer case.
7. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
8. Install the electrical connector to the encoder/motor.
9. Install the vent hose to the transfer case.
10. Install the rear propeller shaft.
11. Install the transfer case shield.
12. Check the transfer case oil level. Add oil as necessary.
13. Lower the vehicle.