Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure





1. Remove the transfer case shield, if equipped.
2. Drain the transfer case of fluid.
3. Remove the front propeller shaft.
4. Remove the rear propeller shaft.
5. Remove the transmission shift control cable clip from the transfer case.
6. Remove the transmission vent hose clip from the bracket, if equipped.





7. Disconnect the speed sensor electrical connector.
8. Disconnect the inline to engine harness electrical connector.
9. Remove the inline connector from the harness bracket.
10. Disconnect the encoder motor electrical connector.
11. Remove the clips from the transfer case brackets.





12. Disconnect the transfer case vent hose.
13. Support the transmission with a suitable transmission jack stand.





14. Remove the transmission mount nuts.





15. Remove the crossmember bolts.
16. Remove the crossmember.





17. Remove the transmission mount bolts
18. Remove the transmission mount from the adapter.
19. Support the transfer case with a suitable jack stand.





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

Important: The following service procedure must be performed with the assistance from another technician.

22. Remove the transfer case, perform the following:
1. Slide the transfer case straight back toward the rear of the vehicle.
2. Rotate the transfer case so that the front output shaft is above the torsion bar bracket.
3. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket.
4. Lower the transfer case.

Installation Procedure

Important: The following installation procedure must be performed with the assistance of another technician.





1. Install the transfer case, perform the following:
1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
2. Rotate the transfer case so that it is in line with the adapter.
3. Install the transfer case to the adapter.

Notice: Refer to Fastener Notice in Service Precautions.

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





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





5. Install the crossmember.
6. Install the crossmember bolts.
^ Tighten the bolts to 70 Nm (52 ft. lbs.).





7. Lower the transmission/transfer case.
8. Install the transmission mount nuts.
^ Tighten the nuts to 40 Nm (30 ft. lbs.).
9. Remove the transmission jack stand.





10. Connect the transfer case vent hose.





11. Install the clips to the transfer case brackets.
12. Connect the encoder motor electrical connector.
13. Install the inline connector to the harness bracket.
14. Connect the inline to engine harness electrical connector.
15. Connect the speed sensor electrical connector.





16. Install the transmission vent hose clip to the bracket, if equipped.
17. Install the transmission shift control cable clip to the transfer case.
18. Install the rear propeller shaft.
19. Install the front propeller shaft.
20. Fill the transfer case with fluid.
21. Install the transfer case shield, if equipped.