Transfer Case: Service and Repair

Fig. 1 Transfer Case Retaining Bolt Tightening Sequence:

1. Raise and support vehicle.
2. Remove skid plate from frame, if equipped, then drain fluid from transfer case.
3. On models with electronic shift, squeeze electrical connector locking tabs together, then disconnect from feed wire harness at rear of transfer case.
4. On models less electronic shift, disconnect four wheel drive indicator switch electrical connector from transfer case.
5. On all models, disconnect front driveshaft from axle input yoke.
6. Loosen clamp retaining front driveshaft boot to transfer case, then remove driveshaft and front boot assembly from transfer case front output shaft.
7. Disconnect rear driveshaft from transfer case output shaft yoke, then the speedometer driven gear from transfer case rear cover.
8. Disconnect vent hose from control lever or mounting bracket.
9. On models less electronic shift, remove shoulder bolt and the shifter to extension housing retaining bolt. Pull control lever out until bushing slides off shift lever pin. If necessary, remove shift lever from control lever.
10. Remove heat shield from transfer case, if equipped.
11. On all models, support transfer case with a suitable jack, then remove retaining bolts. Slide transfer case rearward and lower from vehicle.
12. Reverse procedure to install. Note the following:
a. Torque transfer case retaining bolts to 25-43 ft. lbs. Follow tightening sequence as shown in Fig. 1.
b. Torque heat shield retaining bolts to 27-37 ft. lbs.
c. Torque shifter to extension housing retaining bolt to 31-42 ft. lbs. and shoulder bolt to 70-90 ft. lbs. The shifter retaining bolt must be tightened before the shoulder bolt.
d. Torque speedometer driven gear attaching screw to 20-25 inch lbs., front and rear driveshaft retaining bolts to 12-15 ft. lbs., drain and fill plugs to 14-22 ft. lbs. and mechanical shift skid plate retaining bolts to 22-30 ft. lbs, electronic shift to 15--20 ft. lbs.
e. On 1991 models with electronic shift case, install API GL-4 or GL-5 to bottom of fill hole.
f. On all except 1991 models equipped with electronic shift case, add Mercon automatic transmission fluid until lubricant level reaches bottom of fill hole.