Transfer Case Assembly Replacement
Transfer Case Assembly Replacement
Removal Procedure
1. Drain the transfer case fluid, if necessary. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.
2. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement.
3. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement Front Propeller Shaft Replacement.
4. Remove the transfer case encoder motor. Refer to Transfer Case Encoder Motor Replacement Service and Repair.
5. Disconnect the engine wiring harness electrical connectors (3, 5) from the following:
* The speed sensor (2)
* The heated oxygen sensor pigtail
6. Disconnect the engine wiring harness electrical connectors (1, 2) from the following:
* The brown NEUTRAL switch electrical connector (6)
* The gray 2/4 indicator switch electrical connector (4)
7. Disconnect the engine wiring harness retainers from the transfer case.
8. Position the engine wiring harness aside.
9. If equipped with (MA5) complete the following:
1. Remove the transfer case mounting bolts.
2. With the aid of an assistant, carefully lower the transfer case from the vehicle.
10. If equipped with (M30) complete the following:
1. Remove the transfer case mounting bolts.
2. With the aid of an assistant, carefully lower the transfer case from the vehicle.
Installation Procedure
1. If equipped with (M30) complete the following:
1. With the aid of an assistant, carefully raise the transfer case to the transfer case adapter, aligning the splines.
Caution: Refer to Fastener Caution Fastener Caution.
2. Install the transfer case mounting bolts and tighten to 50 Nm (37 lb ft).
2. If equipped with (MA5) complete the following:
1. Lightly lubricate the transmission rear seal.
Note: Do not catch the input shaft on the transmission rear seal.
2. With the aid of an assistant, carefully raise the transfer case to the manual transmission, aligning the splines.
3. Install the transfer case mounting bolts and tighten to 50 Nm (37 lb ft).
3. Position the engine wiring harness (3) to the transfer case assembly.
4. Connect the engine wiring harness retainers to the transfer case.
5. Connect the engine wiring harness electrical connectors (1, 2) to the following:
* The brown NEUTRAL switch electrical connector (6)
* The gray 2/4 indicator switch electrical connector (4)
6. Connect the engine wiring harness electrical connectors (3, 5) to the following:
* The speed sensor (2)
* The heated oxygen sensor pigtail
7. Install the transfer case encoder motor. Refer to Transfer Case Encoder Motor Replacement Service and Repair.
8. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement Front Propeller Shaft Replacement.
9. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement One-Piece Propeller Shaft Replacement.
10. Fill the transfer case with fluid, if previously drained. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.