Transfer Case Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield. Refer to Shield Replacement.
3. Remove the front propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece or Propeller Shaft Replacement - Three Piece.
4. Remove the vent hose from the transfer case. Refer to Vent Hose.
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.

Notice: Refer to Fastener Notice in Service Precautions.





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





4. Install the transfer case motor/encoder.
5. Remove the jack from the transfer case.
6. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
7. Install the vent hose to the transfer case. Refer to Vent Hose.
8. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - One Piece or Propeller Shaft Replacement - Two Piece or Propeller Shaft Replacement - Three Piece.
9. Install the front propeller shaft. Refer to Propeller Shaft Replacement (Front Axle-All Except NP8).
10. Install the transfer case shield. Refer to Shield Replacement.
11. Lower the vehicle.