Removal and Installation

TRANSFER CASE
Removal

Notice: The transfer case may be removed as a separate unit or as part of the transmission removal depending on the service being performed.

1. Disconnect the negative battery terminal.
2. Remove the rear portion of the center console.





a. Remove two screws from the rear of the center console.
b. Raise emergency brake handle.
c. Remove the rear center console.
3. Loosen the locknuts, then unscrew and remove the knobs from the transfer lever and shift change lever.
4. Remove three screws from the front portion of the center console and remove the console. Slide the boots for the shift change lever and transfer lever over the levers and remove the console.
5. Remove the dust cover plate.





a. Remove five nuts and one bolt.
b. Remove the elate
6. Remove the dust cover over the shift change and transfer levers.
7. Remove the shift change lever.
a. Remove four bolts from the bracket, and the clip from one end of the extension change shaft.
b. Slide the extension change shaft clear of the shift change lever.
8. Remove the transfer lever.





a. Remove five bolts.
b. Remove the transfer lever.
c. Remove the clip from the vehicle speed sensor wire.
9. Raise the vehicle and support it with safety stands.

Notice: Do not let the engine mounts support the transmission during transfer case removal. The engine mounts could be damaged.

10. Remove the plug in the bottom of the transfer case and drain the fluid into a suitable container.
11. Mark the front and rear flanges of both driveshafts for alignment reference.

Notice: Do not separate the two splined sections of the driveshaft. Severe driveshaft vibration may occur if the splined sections are misaligned during reassembly.

12. Remove the four driveshaft bolts at the front differential and the four bolts at the transfer case. Then remove the front driveshaft.





13. Remove all four driveshaft bolts at the rear differential and the four bolts at the transfer case. Remove the rear driveshaft.
14. Disconnect the 4WD indicator light switch connector.
15. Disconnect the vehicle speed sensor connector.
16. Support the transmission on a post jack.
17. Remove two mount bolts and two chassis bolts and remove the transfer case side mount.





18. Remove the eight chassis bolts and four mount bolts and remove the transmission crossmember.
19. Support and secure the transfer case on a jack.
20. Remove ten bolts and separate the transfer case from the transmission.





21. Lower the transfer case and place on a bench.

Installation
1. Mount the transfer case on the jack and secure it to the jack.
2. Jack the transfer case into position and install the ten bolts.
Tighten the bolts to 32 ft. lbs. (44 Nm).
3. Install the transmission crossmember.
Tighten the eight chassis bolts to 32 ft. lbs. (44 Nm).
Tighten the four mounting nuts to 15 ft. lbs. (20 Nm).
4. Reinstall the transfer case side mount.
Tighten the two bolts and two nuts to 38 ft. lbs. (52 Nm).
5. Remove the transmission post jack and the transfer case jack.
6. Reconnect the vehicle speed sensor connector.
7. Reconnect the 4WD indicator light switch connector.
8. Reinstall the front and rear driveshafts.
Tighten the bolts to 27 ft. lbs. (36 Nm).

Notice: Refer to the alignment marks on the flanges for correct orientation of the shaft to the flange. Misalignment of the flanges can cause damage to the transfer case, engine, or driveshafts.

9. Install a new washer on the drain plug and reinstall the plug in the case.
Tighten the plug to 22 ft. lbs. (30 Nm).
10. Add approximately 1.4 quarts (1.3 liters) of 90W gear oil into the oil check/fill hole. The oil level should be even with the bottom of the oil check/fill hole.
11. Install a new washer on the oil check/fill plug and install the plug in the case.
Tighten the plug to 22 ft. lbs. (30 Nm).
12. Lower the vehicle.
13. Reinstall the extension change shaft through the ball end of the shifter and the fork end of the control rod and reinstall the two clips.
14. Bolt the change lever assembly in place.
Tighten the four bolts to 20 ft. lbs. (27 Nm).





15. Apply silicone sealer to the transfer lever assembly and reinstall the assembly. Reinstall the wire harness clip on the forward bolt.
Tighten the four bolts to 20 ft. lbs. (27 Nm).
16. Route the vehicle speed sensor wire through the harness clip.
17. Reinstall the dust cover over the shift change and transfer levers.





18. Reinstall the dust cover plate.
Tighten the five nuts and bolt to 15 ft. lbs. (20 Nm).
19. Reinstall the front console and tighten the three screws.
20. Reinstall the rear console and tighten the two screws.





21. Reinstall the shift knob and transfer lever knob.
22. Reconnect the negative battery terminal.