Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure




1. Remove the transfer case shield, if equipped.
2. Remove the front propeller shaft.
3. Remove the rear propeller shaft.
4. Remove the in-line to engine harness electrical connector (1) from the bracket.
5. Disconnect the gear indicator switch electrical connector (2).
6. Disconnect the speed sensor electrical connector (4).
7. Remove the harness clips (3) from the transfer case.
8. Reposition the harness.




9. Remove the vent hose.
10. Remove the control rod.
11. Support the transmission with a suitable transmission jack stand.
12. Support the transfer case with a suitable jack stand.
13. Remove the crossmember.
14. Remove the transmission mount.
15. Remove the shift control switch harness bracket.
16. Remove the transfer case adapter nuts.

Important: The following service procedure must be performed with the assistance from another technician.




17. Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle.
18. Rotate the transfer case so that the front output shaft is above the torsion bar bracket.
19. Rotate the transfer case (with the input shaft slightly lowered) so that the transfer case is parallel to the torsion bar bracket.
20. Lower the transfer case.

Installation Procedure





Important: The following installation procedure must be performed with the assistance of another technician.

1. Raise the transfer case into position (the transfer case should be parallel to the torsion bar bracket).
2. Rotate the transfer case so that it is in line with the adapter.
3. Install the transfer case.
4. Install the shift control switch harness bracket.

Notice: Refer to Fastener Notice.

5. Install the transfer case adapter nuts.

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

6. Remove the support from the transfer case.
7. Install the transmission mount.
8. Install the crossmember.
9. Remove the transmission jack stand.
10. Install the control rod.




11. Install the vent hose.




12. Position the harness.
13. Install the harness clips (3) to the transfer case.
14. Connect the speed sensor electrical connector (4).
15. Connect the gear indicator switch electrical connector (2).
16. Install the in-line to engine harness electrical connector (1) to the bracket.
17. Install the rear propeller shaft.
18. Install the front propeller shaft.
19. Check the fluid level. Add fluid if necessary.
20. Install the transfer case shield, if equipped.