Transfer Case Installation

Transfer Case

Special Service Tools






Wrench adaptor

303-1069

Installation
1 With assistance, install the transfer case.
- Clean the component mating faces.
- Lubricate input shaft splines with 'Weicon TL7391' grease.
- Install the O-ring seal.
- Using the special tool, tighten the bolts to 45 Nm (33 lb.ft).
2 Connect the breather line.
3 Position the fuel line support bracket.
- Tighten the bolts to 10 Nm (7 lb.ft).
- Secure the fuel lines.
4 Connect the electrical connectors.
5 Secure the wiring harness to the transfer case.
- Secure with the clip.
- Tighten the bolts to 25 Nm (18 lb.ft).
6 Secure the front driveshaft to the transfer case drive flange.
- Stage 1: Tighten the bolts to 45 Nm (33 lb.ft).
- Stage 2: Tighten the bolts a further 90 degrees.
7 Secure the rear driveshaft to the transfer case drive flange.
- Clean the component mating faces.
- Tighten the Torx bolts to 55 Nm (40 lb.ft).
8
CAUTION: Align the driveshaft center bearing mount by moving the floating front section of the shaft backward or forwards until the bolt holes in the mount align with the holes in the chassis.
CAUTION: Make sure the center bearing mount is not under tension.
Install the driveshaft center bearing mount bolts.
- Align the center bearing mount.
- Tighten the driveshaft center bearing retaining bolts to 30 Nm (22 lb.ft).
9 Install the fuel tank heat shield.
- Tighten the bolts to 6 Nm (4 lb.ft).
- Tighten the nuts to 3 Nm (2 lb.ft).

10 Install the ground cable to the transfer box.
- Tighten the bolt to 15 Nm (11 lb.ft).

11 Install the transmission heat shield.
- Tighten the bolts to 10 Nm (7 lb.ft).

12 Install the transmission crossmember. For additional information, refer to Transmission Support Crossmember - 5.0L NA V8 - AJ133 Service and Repair

13 Connect the battery ground cable. For additional information, refer to Specifications Service and Repair

14 Check and top-up the transfer case fluid level.

15 Using the diagnostic tool, re-calibrate the transfer case.