Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Remove the transfer case shield, if equipped.
2. Remove the front propeller shaft.
3. Remove the rear propeller shaft.
4. Drain the transfer case fluid.
5. Remove the transmission vent hose clip from the bracket.
6. Remove the transmission selector cable from the bracket.
7. Disconnect the speed sensor electrical connector (4).
8. Remove the speed sensor wire clip (3) from the bracket.
9. Reposition the speed sensor wire.
10. Remove the engine harness clips (5, 6) from the bracket.
11. Remove the fuel pipe clip from the bracket.
12. Support the transmission with a suitable jack stand.
13. Install a suitable transmission jack under the transfer case.





14. Remove the transmission mount nuts.
15. Raise the transfer case slightly.





16. Remove the transmission mount bolts (1), at the transfer case.





17. Remove the transmission mount.





18. Remove the crossmember bolts.
19. Remove the crossmember.





20. Remove the transfer case adapter nuts.
21. 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.

22. Remove the transfer case.
23. Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
24. Lower the transmission jack.
25. Remove the gasket from the transfer case.
26. Remove the transfer case from the transmission jack.

Installation Procedure





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

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

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 aligned with the adapter.
6. Install the transfer case.
7. Install the fuel pipe bracket onto the studs.

Notice: Refer to Fastener Notice in Service Precautions.

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

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





9. Position the crossmember.
10. Install the crossmember bolts.
^ Tighten the bolts to 95 Nm (70 ft. lbs.).





11. Install the transmission mount.





12. Install the transmission mount bolts (1), to the transfer case.
^ Tighten the bolts to 47 Nm (35 ft. lbs.).

13. Lower the transfer case.





14. Install the transmission mount nuts.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).

15. Remove the jack stand from the transmission.
16. Remove the transmission jack from the transfer case.





17. Install the fuel pipe clip to the fuel pipe bracket.
18. Install the clips (5, 6) to the fuel pipe bracket.
19. Position the speed sensor wire.
20. Install the speed sensor wire clip (3) to the bracket.
21. Connect the speed sensor electrical connector (4).
22. Install the transmission selector cable to the bracket.
23. Install the transmission vent hose clip to the bracket.
24. Install the rear propeller shaft.
25. Install the front propeller shaft.
26. Refill the transfer case with fluid.
27. Install the transfer case shield, if equipped.