Installation

INSTALLATION / NV242 Transfer Case
1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case and transmission shafts and install transfer case on transmission.
5. Install and tighten transfer case attaching nuts.

Transfer Case Attaching Nuts 35 Nm (26 ft. lbs.)

6. Connect vent hose.
7. Connect transfer case position sensor connector to sensor.
8. Align and connect propeller shafts.
9. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
10. Install skid plate.
11. Remove transmission jack and support stand.
12. Connect shift cable to transfer case range lever.
13. Lower vehicle and verify transfer case shift operation.





INSTALLATION / Transfer Case Position Sensor
1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary.
2. Install the transfer case position sensor into the transfer case.

Transfer Case Position Sensor 20 - 34 Nm (15 - 25 ft. lbs.)

3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.



INSTALLATION / Shift Lever
1. Route the shift cable through the opening in the floor pan.
2. Position the shift mechanism over the shifter retaining studs on the floor pan.
3. Install the nuts to hold the shifter mechanism to the floor pan.

Shifter Mechanism Nuts 11.86 Nm (105 in. lbs.).

4. Install any floor console components previously removed.
5. Verify that the floor shifter is in the 4L position.
6. Raise vehicle.
7. Route the shift cable through the opening in the shift cable support bracket.
8. Install the cable and a new spring clip into the slot in the support bracket.
9. Install any additional routing clips on the shift cable.
10. Verify that the transfer case is in the 4L position. The 4L position for the transfer case is with the manual lever to the full rearward position.
11. Attach the shift cable to the transfer case manual lever.
12. Lower vehicle and check for proper transfer case shifter operation.






INSTALLATION / Front Output Shaft Seal
1. Install new front output seal in front case with Installer Tool 6952-A as follows:
a. Place new seal on tool. Garter spring on seal goes toward interior of case.






b. Start seal in bore with light taps from hammer. Once seal is started, continue tapping seal into bore until installer tool seats against case.

2. Install the front output shaft companion flange.
3. Install the front propeller shaft.