Installation

Transfer Case

NOTE: Vehicles with electronic shift transfer case and TorqShift(R) transmission shown, manual shift transfer case and/or TorqShift(R)6 transmission similar.









All vehicles

1. Secure the transfer case to a suitable high-lift transmission jack with a safety strap. Position the transfer case to the extension housing.

Vehicles with TorqShift(R) transmission

2. NOTE: Hand tighten all transfer case-to-transmission bolts. Torque two bolts to specification that are opposite of each other first. Torque each bolt slowly in steps to avoid binding of the transfer case during tightening. After the first two bolts are torqued to specification, no further tightening sequence is required.

Install the 6 transfer case-to-transmission bolts. Remove the transmission jack.

- Tighten to 55 Nm (40 lb-ft).

Vehicles with TorqShift(R)6 transmission

3. NOTE: Hand tighten all transfer case-to-transmission bolts. Torque two bolts to specification that are opposite of each other first. Torque each bolt slowly in steps to avoid binding of the transfer case during tightening. After the first two bolts are torqued to specification, no further tightening sequence is required.

Install the 11 transfer case-to-transmission bolts.

- Tighten to 55 Nm (40 lb-ft).

4. Lift the transfer case up and install the transmission support crossmember. For additional information, refer to Full Frame and Body Mounting Service and Repair. Remove the transmission jacks.

Vehicles with electric shift transfer case

5. Connect the gearmotor encoder electrical connector and the gearmotor electrical connector.





Vehicles with manual shift transfer case

6. Connect the manual shift linkage to the transmission.

7. Connect the 3-position mode switch electrical connector.





All vehicles

8. Connect the vent hose.





9. Remove the high-lift jack.

Vehicles equipped with a flange

10. Align the index marks, then connect the rear driveshaft to the transfer case flange. Install the 4 new rear driveshaft bolts.
- Tighten to 102 Nm (75 lb-ft).

11. Align the index marks, then connect the front driveshaft to the transfer case flange. Install the 4 new front driveshaft bolts.
- Tighten to 111 Nm (82 lb-ft).

Vehicles equipped with a slip yoke

12. Install the driveshaft. For additional information, refer to Driveshaft Diagrams.

13. If equipped, install the transfer case skid plate and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).





14. If drained, fill the transfer case to capacity. For additional information, refer to Transfer Case Draining and Filling Procedures.