Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

(Some people have issue connecting. LEMON is investigating. For now, use Firefox or change your DNS server)

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Gear Sensor/Switch: Service and Repair

REMOVAL
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the position sensor.
3. Remove the position sensor from the transfer case.

INSTALLATION
1. Inspect the O-ring seal on the transfer case position sensor. Replace the O-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 20 - 34 Nm (15 - 25 ft. lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.