Transfer Case Assembly Replacement

Removal Procedure





1. Raise and support the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield. Refer to Shield Replacement.
3. Remove the front and rear propeller shafts. Refer to Propeller Shaft Replacement (4WD and AWD Models).
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.





Notice: Refer to Fastener Notice in Service Precautions.

3. Install the bolts that secure the transfer case to the transmission.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).
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. Refer to Propeller Shaft Replacement (4WD and AWD Models).
9. Install the transfer case shield. Refer to Shield Replacement.
^ Check the transfer case oil level. Add oil as necessary. Refer to Approximate Fluid Capacities.
^ Lower the vehicle.
10. Check the transfer case for normal operation.