Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure
1. Raise the vehicle.
2. Drain the transfer case.
3. Remove the rear propeller Shaft.
4. Remove the front propeller shaft.





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.

11. Disconnect the electrical harness from the top of the transfer case.

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

12. Remove the transfer case.
13. Remove the transfer case gasket (4).

Installation Procedure





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

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.

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

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

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.
10. Install the front propeller shaft.
11. Fill the transfer case with fluid.
12. Lower the vehicle.