Removal Procedure
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
- Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
- Drain the transfer case. Refer to Transfer Case Fluid Replacement .
- Remove the rear propeller shaft from the transfer case. Refer to Rear Propeller Shaft Replacement in Propeller Shaft.
- Remove the front propeller shaft from the transfer case. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Remove the vent hose from the transfer case.
- Remove the electrical connector from the speed sensor.
- Support the transmission with a suitable jack stand.
- Remove the transmission mount from the cross member.
- Remove the rear transmission cross member.
- Install a suitable transmission jack to the transfer case.
- Remove the bolts from the transfer case to the adapter.
- Remove the transfer case from the transfer case adapter.
- Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
- Lower the transfer case.
- Remove the gasket from the transfer case.
- Remove the transfer case from the transmission jack.
Important: Pull straight back on the transfer case in order to position the transfer case so that the transfer case can be turned parallel to the transmission.
Installation Procedure
- Install the transfer case on a suitable transmission jack.
- Install a new transfer case gasket.
- Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
- Raise the transfer case into position.
- Rotate the transfer case so that the transfer case is aligned with the adapter.
- Install the transfer case on the adapter.
- Install the mounting nuts for the transfer case.
- Install the transmission support member.
- Install the transmission mount to the transfer case.
- Remove the transmission jack.
- Install the electrical connector to the speed sensor.
- Install the vent hose to the vent tube.
- Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement in Propeller Shaft.
- Fill the transfer case with the proper transfer case fluid. Refer to Transfer Case Fluid Replacement .
- Install the transfer case shield. Refer to Transfer Case Shield Replacement .
- Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Important: When installing a new transfer case gasket, ensure that the locator tab is facing up for proper installation. Install the gasket without the use of any type of sealant or of lubricant.
Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
Tighten
Tighten the mounting nuts to 50 N·m (37 lb ft).
Tighten
Tighten the cross member mounting bolts to 70 N·m (50 lb ft).
