Installation

Materials

Installation
1. Install a new transfer case-to-transmission gasket.






2. Position the transfer case into the vehicle and install the fuel line bracket and the transfer case-to-transmission bolts.
3. Using suitable jacks, raise the transfer case and transmission completely into position.
4. Remove the transmission jack from under the transfer case.






5. Install the transmission mount.






6. Position the crossmember and loosely install the transmission mount nuts.






7. Install the eight crossmember bolts.






8. Tighten the nuts.
9. Remove the transmission jack from under the transmission.






10. Install the RH crossmember cover and two nuts.






11. Install the RH heat shield-to-crossmember bolts.






12. Install the LH heat shield-to-crossmember bolt.






13. Connect the vent hose.

14. CAUTION: The can (domed CV joint housing cover) is pressed into the CV joint housing at the factory. When housed correctly, the can will appear as shown in the cut-away illustration, top box. Do not reseat the can in the CV joint housing if the can's flange is above the CV joint housings shown in the cut-away illustration, bottom box. Install a new driveshaft.






Verify that the can flange is housed correctly in the CV joint housing as shown in the cut-away illustration top box. Install a new driveshaft if the can flange is not housed correctly.

15. CAUTION: Always connect the front driveshaft to the transfer case first. Otherwise the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.

NOTE: Align the index marks.

Install the driveshaft

16. CAUTION: Tighten the bolts evenly in a cross pattern or damage will occur to the CV joint.






NOTE: Install new washers and bolts. If new bolts are not available coat the threads of the original bolts with threadlock and sealer. Install the new washers and bolts. Tighten the bolts evenly in a cross pattern as shown.






17. Verify that the CV joint has seated squarely in the transfer case flange.
^ Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top to the bottom of the two components.
^ Rotate the driveshaft 1/4 turn.
^ Check that the space between the end of the CV joint cap and the end of the transfer case flange is equal from the top of the bottom of the two components.
^ Repeat this procedure several times.
^ If the space is not equal at any point in the attachment remove and reinstall the driveshaft as described in this procedure.






18. NOTE: Install new universal joint retainers and bolts. If new bolts are not available coat the threads of the original bolts with threadlock and sealer. Install the new universal joint retainer and bolts.






19. Install the skid plate if equipped.

20. CAUTION: Transfer case failure can result if the correct fill procedures are not followed.

NOTE: The fluid level must be just below the fill plug.






Remove the fill plug and check the fluid level. If the fluid is below the proper level fill the transfer case with transmission fluid.
21. Install the rear driveshaft.