Installation

Transfer Case

Transfer Case - With Automatic Transmission (Part 1):

Transfer Case - With Automatic Transmission (Part 2):

Transfer Case - With Manual Transmission (Part 1):

Transfer Case - With Manual Transmission (Part 2):

1. Secure the transfer case to the high-lift jack with a safety strap. Install the new gasket on the transmission, then position the transfer case to the extension housing.
2. Install the 5 transfer case-to-transmission bolts. Tighten the bolts in a clockwise direction beginning with the upper LH bolt.
^ Tighten to 54 Nm (40 lb-ft).

3. Connect the vent hose.
4. Remove the high-lift jack.

5. NOTE: Install the front driveshaft with new bolts and washers. If new bolts are not available, coat the threads of the original bolts with Threadlock(R).

Align the index marks, then connect the front driveshaft to the transfer case flange. Install the 6 front driveshaft-to-CV joint bolts and retainers.
^ Tighten to 30 Nm (22 lb-ft).

6. NOTE: Align the index marks when installing the rear driveshaft.

Install the rear driveshaft.
7. Connect the transfer case electrical connector.





8. Install the 4 skid plate bolts and the skid plate.
^ Tighten to 24 Nm (18 lb-ft).





9. If drained, fill the transfer case with the specified fluid to capacity.