Installation

Transfer Case








1. NOTE: For models with aluminum bolts, a transmission-to-transfer case gasket is not needed. Do not install gasket.

NOTE: Using soapy water in a spray bottle, lubricate the transmission mount rubbers.

Position the transfer case to the transmission and onto the output shaft. With the transfer case 25.4 mm (1 inch) from the transmission, install the transmission mount, then push the transfer case to the transmission.





2. NOTE: Do not reuse the old transfer case-to-transmission bolts.

Install the 9 new transfer case-to-transmission bolts.
^ Tighten the bolts evenly in a star pattern to 20 Nm (15 lb-ft).
3. Install the 4 transmission mount bolts.
^ Tighten to 90 Nm (66 lb-ft).





4. Install the crossmember and the 2 transmission mount nuts. Do not tighten at this time.





5. Install the 4 crossmember bolts and nuts.
^ Tighten the crossmember bolts to 90 Nm (66 lb-ft).
^ Tighten the transmission mount nuts to 25 Nm (18 lb-ft).





6. Install the LH exhaust heat shield bolt and the evaporative emissions canister bolt.
^ Tighten to 15 Nm (11 lb-ft).





7. Install the RH exhaust heat shield.
^ Tighten to 15 Nm (11 lb-ft).





8. Connect the vent hose.
9. Connect the shift motor electrical connector and attach the harness connector to the transfer case.





10. NOTE: Align the index marks made during removal.

Install the rear driveshaft.

11. NOTE: Align the index marks made during removal.

Install the front driveshaft.
12. Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling in General Procedures.
13. Install the skid plate and the 2 skid plate-to-crossmember bolts and the 4 skid plate-to-frame bolts.
^ Tighten to 24 Nm (18 lb-ft).