Transfer Case: Service and Repair

NEW PROCESS 207 & 231

1. Shift transfer case into 4-High position.
2. Raise and support vehicle, then drain lubricant from case.
3. Scribe alignment marks on rear axle yoke and propeller shaft, then remove rear propeller shaft.
4. Disconnect speedometer cable, vacuum hoses and vent hose.
5. Raise transmission and transfer case, then remove crossmember attaching bolts and the crossmember.
6. Scribe alignment marks on front output shaft flange and propeller shaft, then disconnect front propeller shaft from transfer case.
7. Disconnect shift lever linkage rod, then remove shift lever bracket bolts.
8. Support transfer case, then remove attaching bolts.
9. Remove transfer case from vehicle.
10. Reverse procedure to install. Torque transfer case attaching bolts to 26 ft. lbs. and crossmember to frame attaching nuts and bolts to 30 ft. lbs.




NEW PROCESS 228, 229 & 242

1. Raise and support vehicle, then drain lubricant from case.
2. Disconnect speedometer cable and vent hose.
3. Disconnect transfer case shift lever link from operating lever.
4. Support transmission, then remove rear crossmember attaching bolts and the rear crossmember.
5. Scribe alignment marks on transfer case yokes and propeller shafts, then disconnect propeller shafts from transfer case.
6. Disconnect shift motor vacuum hoses.
7. Disconnect transfer case shift linkage, then remove transfer case to transmission attaching bolts.
8. Move transfer case rearward until clear of transmission output shaft and remove from vehicle.
9. Reverse procedure to install. Torque transfer case attaching bolts to 40 ft. lbs. and crossmember to frame attaching nuts and bolts to 30 ft. lbs.