Removal Procedure
- Remove the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
- Drain the fluid from the transfer case.
- Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or, Two-Piece Propeller Shaft Replacement in Propeller Shaft.
- Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Remove the vent hose.
- Remove the vent hose clip from the fuel pipe bracket.
- Remove the shift cable clip from the fuel pipe bracket.
- Remove the speed sensor wire clip from the fuel pipe bracket.
- Disconnect the speed sensor electrical connector.
- Support the transmission with a suitable jack stand.
- Remove the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
- Remove the transmission mount bolts (1).
- Remove the transmission mount.
- Install a suitable transmission jack to the transfer case.
- Remove the transfer case nuts.
- Remove the fuel pipe bracket from the studs.
- Separate the transfer case from the adapter.
- Rotate the transfer case so that it is perpendicular to the torsion bar mounting bracket.
- Lower the transfer case.
- Remove the gasket from the transfer case.
- Remove transfer case from the transmission jack.
Important: When performing this service procedure, pull straight back on the transfer case so that it is in a position so that it can be turn to a parallel to the transmission.
Installation Procedure
- Install the transfer case on a suitable transmission jack.
- Install a NEW transfer case gasket.
- Rotate that transfer case so that it is parallel to the torsion bar mounting bracket.
- Raise the transfer case into position.
- Rotate the transfer case so that it is in line with the adapter.
- Install the transfer case onto the adapter.
- Install the fuel pipe bracket onto the studs.
- Install the transfer case nuts.
- Install the transmission mount.
- Install the transmission mount bolts (1).
- Install the transmission support. Refer to Transmission Support Replacement in Frame and Underbody.
- Remove the transmission jack.
- Connect the speed sensor electrical connector.
- Install the speed sensor wire clip to the fuel pipe bracket.
- Install the shift cable clip to the fuel pipe bracket.
- Install the vent hose clip to the fuel pipe bracket.
- Install the vent hose.
- Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement or, Two-Piece Propeller Shaft Replacement in Propeller Shaft.
- Check the fluid level. Add fluid if necessary.
- Install the transfer case shield, if equipped. Refer to Transfer Case Shield Replacement .
Important: When installing a new transfer case gasket, make sure that the locating tab is pointing up for proper installation. Install the gasket without the use of any type of sealant or grease.
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 nuts to 50 N·m (36 lb ft).
