Main Case

Removal
1. Raise the vehicle and support it on jack stands.
2. Disconnect battery ground cable.
3. Drain fluid.
4. Support transfer case with a jack and remove third crossmember.
5. Remove sixteen 10 mm screws, main case oil pan, magnet and gasket.
6. Remove three 13 mm oil filter fixing screws, then remove oil filter.
7. Remove two 13 mm manual detent fixing screws, then remove roller and spring assembly.
8. Disconnect wiring harness from band control solenoid and shift solenoids. Pull only on connectors, not on wiring harness.
9. Remove four 13 mm servo cover fixing screws, then remove servo cover and gasket.
10. Remove seven 13 mm valve body fixing screws.
^ Disconnect the ground wire from the main case valve body.
11. Remove main case valve body with manual valve link and transfer plate. Note the position of the link (long end into valve, short end into range selector lever).
12. Remove transfer plate gasket from main case.
13. Remove two check balls from main case.

Installation
To install, follow the removal steps in the reverse order, noting the following points:





1. Install two check balls to main case.
2. Inspect electrical 4 pin connector and seal of main case. Replace if necessary.
3. Use two J-25025-B guide pin to install main case.
^ Install valve body assembly and manual valve link.

Notice: Valve must be extended as the short end of manual valve link is connected to the range selector lever. Long end of link goes into valve.





4. Install seven 13 mm screws, and tighten them to the specified torque.
Torque: 20 Nm (15 ft. lbs.)





5. Install 8.5 mm connector of ground wire the head of this valve body bolt and reinstall it. Tighten the bolt to the specified torque.
Torque: 20 Nm (15 ft. lbs.)
6. Remove two guide pins from main case.
7. Install servo cover gasket, cover, and four 13 mm screws. Tighten the screws to the specified torque.
Torque: 25 Nm (18 ft. lbs.)
8. Connect wiring harness to band control and shift solenoids.
9. Install roller and spring assembly to manual detent.
Install two 13 mm screws, and tighten them to the specified torque.
Torque: 20 Nm (15 ft. lbs.)
10. Install oil filter and three 13 mm screws. Tighten the screws to the specified torque.
Torque: 20 Nm (15 ft. lbs.)
11. Install oil pan gasket, magnet, oil pan and sixteen 10 mm screws. Tighten the screws to the specified torque.
Torque: 11 Nm (96 inch lbs.)
12. Install third crossmember and rear mount. Tighten the bolts and nuts to the specified torque.
Torque
Third crossmember bolt: 50 Nm (37 ft. lbs.)
Rear mount nut: 50 Nm (37 ft. lbs.)
13. Fill transmission through overfill screw hole of oil pan, using ATF DEXRON(R) III. Refer to Automatic Transmission Fluid; Service and Repair.
14. Connect battery ground cable.