Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Raise and suitably support the vehicle. Refer to Vehicle Lifting in Service Precautions.
2. Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement.
3. Remove the rear propeller shaft.
4. Remove the front propeller shaft.
5. Drain the fluid from the transfer case.
6. Disconnect the speed sensor electrical connector (4).
7. Remove the clip (3) from the transfer case bracket.
8. Reposition the speed sensor wire.
9. Remove the clips (5, 6) from the fuel pipe bracket.
10. Remove the fuel pipe clip from the fuel pipe bracket.
11. Support the transmission with a suitable jack stand.





12. Remove the transmission mount nuts.





13. Remove the crossmember bolts.
14. Remove the crossmember.
15. Install a suitable transmission jack to the transfer case.





16. Remove the transfer case adapter nuts.
17. Remove the fuel pipe bracket from the studs.

Important: Pull straight back on the transfer case in order to position the transfer case so that it can be rotated parallel to the transmission.

18. Remove the transfer case from the adapter.
19. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
20. Lower the transfer case.
21. Remove the gasket from the transfer case.
22. Remove the transfer case from the transmission jack.

Installation Procedure





1. Install the transfer case onto a suitable transmission jack.

Important: When installing a new transfer case gasket, the gasket must be installed with the tab oriented up, and the yellow printing towards to front of the vehicle. Install the gasket without the use of any type of sealant or of lubricant.

2. Install a NEW transfer case gasket.
3. Rotate the transfer case so that it is parallel to the torsion bar mounting bracket.
4. Raise the transfer case into position.
5. Rotate the transfer case so that it is aligned with the adapter.
6. Install the transfer case to the adapter.
7. Install the fuel pipe bracket onto the studs.

Notice: Refer to Fastener Notice in Service Precautions.

Important: Ensure that the gasket is flush to the transmission prior to installing the nuts.

8. Install the transfer case adapter nuts.
^ Tighten the nuts to 50 Nm (37 ft. lbs.).





9. Position 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 jack stand from the transmission.





13. Install the fuel pipe clip to the fuel pipe bracket.
14. Install the clips (5, 6) to the fuel pipe bracket.
15. Position the speed sensor wire.
16. Install the clip (3) to the transfer case bracket.
17. Connect the speed sensor electrical connector (4).
18. Install the front propeller shaft.
19. Install the rear propeller shaft.
20. Fill the transfer case with fluid.
21. Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement.
22. Lower the vehicle.