Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Drain the transfer case. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
3. Remove the rear propeller Shaft. Refer to Rear Propeller Shaft Replacement (Rear Propeller Shaft Replacement).
4. Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).




5. Remove the electrical harness from the retainer.




6. Disconnect the electrical connector from the speed sensor.




7. Disconnect the vent hose.
8. Install a transmission jack for the transfer case.




9. Remove the transfer case adapter (2) to transfer case nuts (5).
10. Lower the transfer case.

Important: The transfer case gasket may become damaged during the removal procedure.


11. Disconnect the electrical harness from the top of the transfer case.
12. Remove the transfer case.
13. Remove the transfer case gasket (4).

Installation Procedure





Important: If the transfer case gasket is damaged, replace it. DO NOT use silicone sealant in place or with the transfer case gasket.


1. Install or replace the transfer case gasket (4).
2. Raise the transfer case and install the electrical harness.
3. Install the transfer case (3) in the vehicle.

Notice: Refer to Fastener Notice (Fastener Notice).

4. Install the transfer case adapter (2) to transfer case nuts (5). Ensure the fuel line retainer (1) is in place.

Tighten the nuts to 47 Nm (35 ft. lbs.).

5. Remove the transmission jack stand.




6. Connect the electrical connector to the speed sensor.




7. Connect the vent hose.
8. Install the transfer case harness to the transfer case.




9. Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (Rear Propeller Shaft Replacement).
10. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).
11. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
12. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).