Transfer Case Assembly Replacement

Transfer Case Assembly Replacement
Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield.
3. Drain the transfer case of fluid.
4. Remove the front propeller shaft.
5. Remove the rear propeller shaft.
^ For vehicles equipped with the one piece propeller shaft, refer to Propeller Shaft Replacement - One Piece.
^ For vehicles equipped with the two piece propeller shaft, refer to Propeller Shaft Replacement - Two Piece.





6. Remove the transmission shift control cable from the transfer case.





7. Remove the transfer case speed sensor electrical connector.




8. Remove the motor encoder electrical connector.





9. Remove the transfer case vent hose.
10. Support the transmission with a suitable transmission jack stand.





11. Remove the transmission mount retaining nuts.
12. Raise the transmission high enough in order to remove the transmission mount.





13. Remove the transmission Support mounting bolts.
14. Remove the transmission support from the frame.
15. Support the transfer case with a suitable jack stand.





16. Remove the transmission mount bolts
17. Remove the transmission mount from the adapter.





18. Remove the retaining nuts for the transfer case adapter.

Important: The following service procedure must be performed with the assistance from another technician.

19. Slide the transfer case straight back toward the rear of the vehicle.
20. Rotate the transfer case so that the front output shaft is above the torsion bar bracket.
21. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket.
22. Lower the transfer case.

Installation Procedure

Important: The following installation procedure must be performed with the assistance of another technician.





1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
2. Rotate the transfer case so that it is in line with the transfer case adapter.
3. Install the transfer case to the transfer case adapter.





Notice: Refer to Fastener Notice in Service Precautions.
4. Install the transfer case retaining nuts.
^ Tighten the transfer case retaining nuts to 50 Nm (36 ft. lbs.).
5. Install the transmission mount assembly.
6. Install the transmission mount bolts.
^ Tighten the transmission mount bolts to 47 Nm (34 ft. lbs.).





7. Install the transmission support to the frame.





8. Install the transmission support mounting bolts.
^ Tighten the transmission support mounting bolts to 70 Nm (51 ft. lbs.).
9. Lower the transmission/transfer case assembly to the transmission support.
10. Install the transmission mount retaining nuts.
^ Tighten the transmission mount retaining nuts to 40 Nm (29 ft. lbs.).
11. Remove the transmission jack stand.





12. Install the transfer case speed sensor electrical connector.





13. Install the electrical connector to the motor encoder.





14. Install the transfer case vent hose.





15. Install the transmission shift control cable to the transfer case.
16. Install the rear propeller shaft.
^ For vehicles equipped with the one piece propeller shaft, refer to Propeller Shaft Replacement - One Piece.
^ For vehicles equipped with the two piece propeller shaft, refer to Propeller Shaft Replacement - Two Piece.
17. Install the front propeller shaft.
18. Fill the transfer case with the approved fluid.
19. Install the transfer case shield.
20. Lower the vehicle. Refer to Vehicle Lifting.