Transfer Case Replacement

Transfer Case Component Location:

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a fastener needs to be replaced, use the correct part number fastener for that application. if the correct part number fastener is not available, a fastener of equal size and strength (or stronger may be used. Fasteners that are not reused, and those requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage could result.


Remove or Disconnect
1. Negative battery cable.

^ Raise the vehicle. Support with safety stands.

2. Skid plate (if equipped).

^ Drain the oil from the transfer case.

3. Front propeller shaft.

4. Left strut rod.

5. Rear propeller shaft.

6. Electrical connections at the transfer case.

7. Transfer case shift linkage at the transfer case.

^ Support the transfer case with a jack.

8. Bolts (122) and spring washers (123) (if used).

9. Gasket (121).


Install or Connect
1. New gasket (121) to the transmission. Use gasket sealer to hold it in place.

2. Transfer case to the vehicle.

3. Bolts (122) and spring washers (123) (if used). Refer to Notice.

Tighten
^ Bolts to 33 Nm (24 ft. lbs.).

^ Remove the jack from the transfer case.

4. Transfer case shift linkage at the transfer case.

5. Electrical connections to the transfer case.

6. Rear propeller shaft.

7. Left strut rod.

8. Front propeller shaft.

9. Skid plate (if equipped).

^ Fill the transfer case with the proper lubricant.

^ Lower the vehicle.

10. Negative battery cable.