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. Remove the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (Rear Propeller Shaft Replacement).
3. Drain the transfer case. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).




4. Remove the fuel lines from the retainer.




5. Remove the electrical harness from the retainer (right side).




6. Remove the electrical harness from the retainer (left side).




7. Disconnect the electrical connectors from the speed sensors (front speed sensor shown).
8. Disconnect the motor/encoder electrical connector.




9. Remove the transfer case wiring harness.




10. Disconnect the vent hose.
11. Install a transmission jack for the transfer case.




12. Remove the transfer case adapter (2) to transfer case nuts (5).

Important: While removing the transfer case the front propeller shaft must be disconnected from the transfer case. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).


13. Remove the transfer case (3) from the vehicle.

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


14. 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.


Important: While installing the transfer case the front propeller shaft must be connected to the transfer case. Refer to Front Propeller Shaft Replacement (Front Propeller Shaft Replacement).


1. Install or replace the transfer case gasket (4).
2. Install the transfer case (3) in the vehicle.

Notice: Refer to Fastener Notice (Fastener Notice).

3. 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.).

4. Remove the transmission jack stand.




5. Connect the electrical connectors to the speed sensors (front speed sensor shown).




6. Connect the vent hose.
7. Connect the motor/encoder electrical connector.




8. Install the transfer case harness to the transfer case.




9. Install the transfer case wiring harness to the retainers (left side).




10. Install the transfer case wiring harness to the retainers (right side).




11. Install the fuel lines to the retainer.
12. Install the rear propeller shaft. Refer to Rear Propeller Shaft Replacement (Rear Propeller Shaft Replacement).
13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
14. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).