Transfer Case Replacement (Auto Four Wheel Drive)

REMOVAL PROCEDURE
1. Raise and support the vehicle. Refer to Vehicle Lift Points.
2. Remove the transfer case shield. Refer to Shield Replacement.
3. Remove the front propeller shaft. Refer to Propeller Shaft Replacement-Two-Piece.
4. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement (System Balanced Assembly).
5. Disconnect the vehicle speed sensor electrical connector.





6. Disconnect the wiring harness from the transfer case.





7. Remove the transfer case motor/encoder.
Support the transfer case with a jack.





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





10. 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. Install the transfer case motor/encoder.
5. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
6. Install the rear propeller shaft. Refer to Propeller Shaft Replacement (System Balanced Assembly).
7. Remove the jack from the transfer case.
8. Install the front propeller shaft. Refer to Propeller Shaft Replacement (Front Axle-All Except NP8).
9. Install the transfer case shield. Refer to Shield Replacement.
^ Check the transfer case lubricant level. Add oil as necessary. Refer to Approximate Fluid Capacities.
^ Lower the vehicle.