Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure

1. Raise the vehicle. Refer to Vehicle Lifting.
2. Drain the transfer case. Refer to Transfer Case Fluid Replacement.
3. Drain the transmission fluid. Refer to Automatic Transmission Fluid and Filter Replacement.
4. Remove the transmission support member.
5. Remove the rear propeller shaft from the transfer case.
6. Remove the front propeller shaft from the transfer case.




7. Remove the vent hoses from the transfer case and transmission.




8. Disconnect the electrical connector from the speed sensor.
9. Disconnect the encoder motor from the electrical connector.
10. Remove the fuel lines from the retainer at the top of the transfer case.
11. Install a suitable transmission jack to the transfer case.
12. Remove the bolts from the transfer case to the adapter.





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.

13. Remove the transfer case from the transfer case adapter.
14. Rotate the transfer case so that the transfer case is perpendicular to the torsion bar mounting bracket.
15. Lower the transfer case.
16. Remove the gasket from the transfer case.
17. Remove the transfer case from the transmission jack.

Installation Procedure




1. Install the transfer case on a suitable transmission jack.

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 lubricant.

2. Install a new transfer case gasket.
3. Rotate the transfer case so that the transfer case is parallel to the torsion bar mounting bracket.
4. Raise the transfer case into position.
5. Rotate the transfer case so that the transfer case is aligned with the adapter.
6. Install the transfer case on the adapter.

Notice: Refer to Fastener Notice.

7. Install the mounting nuts for the transfer case.

Tighten the mounting nuts to 50 N.m (37 lb ft).

8. Connect the vent hoses to the transfer case and transmission.
9. Connect the vehicle speed sensor and encoder motor electrical connectors.
10. Install the fuel lines into the retainer at the top of the transfer case.




11. Install the transmission support member.
12. Remove the transmission jack.
13. Install the front propeller shaft.
14. Install the rear propeller shaft.
15. Fill the transfer case with the proper transfer case fluid. Refer to Transfer Case Fluid Replacement.
16. Lower the vehicle. Refer to Vehicle Lifting.
17. Fill the transmission fluid with the proper fluid. Refer to Automatic Transmission Fluid and Filter Replacement.