Repair Procedure

1. Support vehicle on a lift, but do not raise the vehicle at this time.





2. Shift the transfer case range lever into the 4L (low) position. Remove the transfer case range selector bezel from the center console.

3. Shift the transmission to the neutral position. Remove the transmission shifter handle. Remove the transmission shifter bezel from the center console.

4. Remove the center console attaching screws (six) and remove the center console.

5. Remove the rear passenger center air duct.

6. Cut through the narrow strap of carpet located in front of the transmission shifter assembly (Fig. 1).





7. Fold the carpet, that is in front of the driver's seat, back towards the driver side door and driver seat (Fig. 2).

8. Remove the four (4) bolts used to retain the transfer case frame bracket to the vehicle body. The bolts are located on the driver's side of the transmission tunnel.

9. Raise and support the vehicle.





10. Remove the frame bracket from the torque shaft (Fig. 3).

11. Remove the transfer case torque shaft by prying the shaft out of the green torque shaft bushing in the transmission bracket.

12. Remove the ends of the shift rod and the torque shaft rod from the torque shaft.

13. Liberally lubricate the frame bracket bushing and both ends of the new torque shaft with multipurpose grease, p/n 04318063 or equivalent.

14. Install the torque shaft assembly to the transmission bracket bushing.

15. Install the frame bracket to the torque shaft.

16. Carefully position the frame bracket to the underbody floor pan. As an assist, temporarily installing a small guide rod (or nail) in a couple of the bolt holes may help with later bolt hole alignment.

17. Lower the vehicle.

18. Attach the frame bracket to the vehicle body with the four (4) bolts. Tighten the bolts to 5.1 Nm (45 in. lbs.).

19. Verify that the transfer case range lever is fully seated in the 4L position.

20. Raise and support the vehicle.

21. Install the end of the torque shaft rod to the new torque shaft.

22. Loosen the lock nut on the shift rod trunnion so that the trunnion will slide easily on the shift rod.

23. Connect the end of the shift rod to the new torque shaft.

24. With the range lever in 4L, tighten the trunnion lock bolt.

25. Lower the vehicle and verify transfer case shift operation.

26. Make sure the floor pan area around the four (4) frame bracket attaching bolts is clean.

27. Make sure floor is clean and install the sound deadener mastic patch, p/n 55352840AA.

28. Install the driver side floor carpeting. Make certain it is centered properly.

29. Install the rear passenger center air duct.

30. Install the center console.

31. Install both shifter bezels and gear shifter handle.

32. Verify proper operation of the gear shifter and transfer case shifter.