Removal and Replacement

Remove/install transfer case










Remove

Danger:
- Lethal injuries are possible if vehicle slips off of lifting platform
- Align vehicle between the columns of the lifting platform and position the four support plates at the lifting platform support points specified by the vehicle manufacturer

1 Raise vehicle with vehicle lift.
2 Detach exhaust shielding plate (41) for rear engine mount from reinforcement brace.
3 Remove exhaust bracket (44).
4 Detach transmission ground (W49) from transfer case (16).
5 Mark propeller shaft of front axle gear (70) relative to flange of transfer case.
6 Detach front axle gear propeller shaft (70) from transfer case (16).
7 Support automatic transmission (17) with transmission jack and transmission platform.
8 Remove rear engine crossmember (42) and rear engine mount.
9 Detach front propeller shaft from transfer case (16).

NOTE: The flexible coupling remains on the transmission propeller shaft

10 Loosen fitted sleeves of flexible coupling and push back propeller shaft.
11 Lower automatic transmission slightly.
12 Detach transfer case (16) from automatic transmission (17).

NOTE: Four nuts and seven bolts

Install

CAUTION: Notes on self-locking nuts and bolts

13 Coat plug-type splines in transfer case (16) with grease.
14 Mount transfer case (16) to automatic transmission (17).

NOTE: Both centering sleeves (arrows) have to be firmly seated in the automatic transmission (17), if necessary replace centering sleeves.
NOTE: Four nuts and seven bolts.

15 Check oil level in transfer case (16), correct if necessary.

NOTE: Use transmission jack and transmission platform to raise the automatic transmission (17) until the transfer case (16) is located in the installation position.

16 Mount front propeller shaft on transfer case (16).

17 Install rear engine crossmember (42) and rear engine mount.
18 Remove assembly lift and transmission platform.
19 MAttach exhaust shielding plate (41) for rear engine mount to reinforcement brace.
20 Mount exhaust bracket (44).

CAUTION: Check threaded tapping plates (44a) and replace if necessary.

21 Attach transmission ground (W49) to transfer case (16).
22 Attach propeller shaft of front axle gear (70) to flange of transfer case.

NOTE: Observe marking.

23 Lower vehicle with lifting platform.