Transfer Case Assembly Replacement
Transfer Case Assembly ReplacementRemoval Procedure
1. Remove the transfer case shield, if equipped.
2. Drain the fluid from the transfer case.
3. Remove the rear propeller shaft.
4. Remove the front propeller shaft.
5. Remove the vent hose.
6. Remove the vent hose clip from the fuel pipe bracket.
7. Remove the shift cable clip from the fuel pipe bracket.
8. Remove the speed sensor wire clip from the fuel pipe bracket.
9. Disconnect the speed sensor electrical connector.
10. Support the transmission with a suitable jack stand.
11. Remove the transmission support.
12. Remove the transmission mount bolts (1).
13. Remove the transmission mount.
14. Install a suitable transmission jack to the transfer case.
15. Remove the transfer case nuts.
16. Remove the fuel pipe bracket from the studs.
Important: When performing this service procedure, pull straight back on the transfer case so that it is in a position so that it can be turn to be parallel to the transmission.
17. Separate the transfer case from the adapter.
18. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
19. Lower the transfer case.
20. Remove the gasket from the transfer case.
21. Remove transfer case from the transmission jack.
Installation Procedure
1. Install the transfer case on a suitable transmission jack.
Important: When installing a new transfer case gasket, make sure that the locating tab is pointing up for proper installation. Install the gasket without the use of any type of sealant or grease.
2. Install a NEW transfer case gasket.
3. Rotate that 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 in line with the adapter.
6. Install the transfer case onto the adapter.
7. Install the fuel pipe bracket onto the studs.
Notice: Refer to Fastener Notice in Service Precautions.
8. Install the transfer case nuts.
^ Tighten the nuts to 50 Nm (36 ft. lbs.).
9. Install the transmission mount.
10. Install the transmission mount bolts (1).
11. Install the transmission support.
12. Remove the transmission jack.
13. Connect the speed sensor electrical connector.
14. Install the speed sensor wire clip to the fuel pipe bracket.
15. Install the shift cable clip to the fuel pipe bracket.
16. Install the vent hose clip to the fuel pipe bracket.
17. Install the vent hose.
18. Install the front propeller shaft.
19. Install the rear propeller shaft.
20. Check the fluid level. Add fluid if necessary.
21. Install the transfer case shield, if equipped.