Transfer Case: Service and Repair

REMOVAL PROCEDURE
1. Raise the vehicle.
2. Remove the front propeller shaft.
3. Remove the rear propeller shaft.
4. Disconnect the vehicle speed sensor electrical connector.





5. Disconnect the wiring harness from the transfer case.





6. Disconnect the transfer case shift cable at the transfer case.
Support the transfer case with a jack.





7. Remove the bolts securing the transfer case to the transmission adapter.
8. Remove the gasket.





9. Discard the 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. Remove the jack from the transfer case.
5. Install the transfer case shift linkage at the transfer case.
6. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
7. Install the front propeller shaft.
8. Install the rear propeller shaft.
9. Check the transfer case lubricant level. Add oil as necessary.
10. Lower the vehicle.