Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Remove the transfer case shield, if equipped.
2. Drain the transfer case fluid.
3. Remove the front propeller shaft.
4. Remove the rear propeller shaft.
5. Remove the vent hose (2) from the transfer case fitting (1).
6. Reposition the vent hose out of the way.





7. Remove the harness inline to engine harness connector clip from the fuel feed and return pipe bracket.
8. Disconnect the encoder motor electrical connector (2).
9. Disconnect the speed sensor electrical connectors (1).
10. Remove the harness clips from the transfer case.
11. Reposition the harness out of the way.

Important: Ensure that the transfer case is correctly secured to the transmission jack.

12. Support the transmission and transfer case with suitable transmission jacks.





13. Remove the transmission mount nuts.





14. Remove the crossmember bolts.
15. Remove the crossmember.





16. Remove the transmission mount bolts.





17. Remove the transmission mount.





18. Remove the transfer case adapter nuts.
19. Remove the fuel feed and return pipe bracket.
20. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle.
21. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
22. Lower the transfer case.

Installation Procedure





1. Rotate the transfer case so that the transfer case is perpendicular to the transmission.
2. Raise the transfer case into position.
3. Rotate the transfer case so that the transfer case aligns with the transfer case adapter.
4. Install the transfer case.
5. Install the fuel feed and return pipe bracket.

Notice: Refer to Fastener Notice in Service Precautions.

6. Install the transfer case adapter nuts.

^ Tighten the nuts to 50 Nm (37 ft. lbs.).





7. Install the transmission mount.





8. Install the transmission mount bolts.
^ Tighten the bolts to 47 Nm (35 ft. lbs.).





9. Install the crossmember.
10. Install the crossmember bolts.
^ Tighten the bolts to 70 Nm (52 ft. lbs.).





11. Install the transmission mount nuts.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).
12. Remove the transmission jacks from the transmission and transfer case.





13. Position the harness to the transfer case.
14. Install the harness clips to the transfer case.
15. Connect the speed sensor electrical connectors (1).
16. Connect the encoder motor electrical connector (2).
17. Install the harness inline to engine harness connector clip to the fuel feed and return pipe bracket.





18. Position the vent hose to the transfer case.
19. Install the vent hose (2) to the transfer case fitting (1).
20. Install the rear propeller shaft.
21. install the front propeller shaft.
22. Fill the transfer case with fluid.
23. Install the transfer case shield, if equipped.