New Assembly

Removal

CAUTION: A breakaway pin, found only on a new transfer case control lever assembly detent plate, holds the lower shifter arm in the 2H detent position during installation. This ensures correct transfer case gear engagement during transfer case operation. Carry out this procedure only if installing a new transfer case control lever assembly. If reinstalling the original transfer case control lever assembly, refer to Transfer Case Shift Lever-Original Assembly.

1. Shift the transfer case into 2H.





2. Remove the screws that attach the bezel and boot assembly to the floor.





3. Remove the bolt that attaches the shift lever to the transfer case control lever assembly, and remove the shift lever, and the bezel and boot assembly.
1. Slide the bezel and boot assembly upward on the shift lever.
2. Remove the bolt, the shift lever, and the bezel and boot assembly.
4. Raise and support the vehicle.





5. Disconnect the control rod from the lower shifter arm.





6. Remove the bolt and the transfer case control lever assembly.

Installation

CAUTION: A breakaway pin, found only on a new transfer case control lever assembly detent plate, holds the lower shifter arm in the 2H detent position during installation. This ensures correct transfer case gear engagement during transfer case operation. Carry out this procedure only if installing a new transfer case control lever assembly. If reinstalling the original transfer cast control lever assembly, refer to Transfer Case Shift Lever-Original Assembly.





1. Verify that the breakaway pin on the detent plate is inserted into the hole in the lower shifter arm.

2. CAUTION: Do not tighten the bolt that attaches the transfer case control lever assembly to the transmission case at this time.





Align the transfer case control lever assembly pivot bolt over the correct mounting hole in the transmission case and start the bolt into the threaded hole by hand.
1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, install the bolt in the forward (LH) threaded hole in the transmission case.
2. For vehicles with a gasoline engine and automatic transmission, install the bolt in the rearward (RH) threaded hole in the transmission case.





3. Position the detent plate locating pin in the unused threaded hole in the transmission case.
1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, position the pin in the rearward (RH) threaded hole in the transmission case.
2. For vehicles with a gasoline engine and automatic transmission, position the pin in the forward (LH) threaded hole in the transmission case.

4. CAUTION: Verify that the control rod is still attached correctly to the transfer case.

CAUTION: Verify that the transfer case is still in 2H.





Connect the control rod to the lower shifter arm.





5. Hold the transfer case control lever assembly and tighten the bolt.
6. Lower the vehicle.





7. Position the shift lever with the bezel and boot assembly and install the bolt.





8. Position the bezel and boot assembly and install the screws.
9. Shift the transfer case shift lever to break the locating pin. Verify the shift sequence from 2H to 4L to 2H.