Installation

Transfer Case





Transfer Case

NOTE: Automatic transmission shown, manual transmission similar.











1. Secure the transfer case to the high-lift jack with a safety strap. Install the new gasket on the transmission and position the transfer case to the extension housing.

2. Install the 5 transfer case-to-transmission bolts. Tighten the bolts in a clockwise direction beginning with the upper LH bolt.
- Tighten to 54 Nm (40 lb-ft).

3. Connect the vent hose.

4. Remove the high-lift jack.

5. NOTICE: The front driveshaft must be connected to the transfer case last. The weight of the driveshaft may pinch the boot between the shaft and the boot and cause the boot to tear.

NOTE: Install the front driveshaft with new bolts and washers. If new bolts are not available, apply threadlock to the threads of the original bolts.

Align the index marks, then connect the front driveshaft to the transfer case flange. Install the 6 front driveshaft-to-CV-joint retainers and bolts.

- Tighten to 30 Nm (22 lb-ft).

6. NOTE: Align the index marks when installing the rear driveshaft.

Install the rear driveshaft. For additional information, refer to Driveshaft Removal and Replacement.

7. Connect the transfer case electrical connector.





8. Install the 4 skid plate bolts and the skid plate.
- Tighten to 24 Nm (18 lb-ft).





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