Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure
1. Drain the transfer case fluid, if necessary.
2. Remove the rear propeller shaft.
3. Remove the front propeller shaft.
4. Remove the transfer case encoder motor.





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.

2. Notice: Refer to Fastener Notice in Service Precautions.

Install the transfer case mounting bolts.
^ Tighten the transfer case mounting bolts to 50 Nm (37 ft. lbs.).





2. If equipped with (MA5) complete the following:
1. Lightly lubricate the transmission rear seal.

2. Important: Do not catch the input shaft on the transmission rear seal.

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.
^ Tighten the transfer case mounting bolts to 50 Nm (37 ft. lbs.).





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)





1. Connect the engine wiring harness electrical connectors (3, 5) to the following:
^ The speed sensor (2)
^ The heated oxygen sensor pigtail
2. Install the transfer case encoder motor.
3. Install the front propeller shaft.
4. Install the rear propeller shaft.
5. Fill the transfer case with fluid, if previously drained.