Case Adapter: Service and Repair

Transfer Case Adapter Replacement

Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Support the transmission with a suitable jack stand.




3. Remove the rear crossmember from the frame.
4. Remove the transfer case from the vehicle. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).




5. Remove the mounting bolts from the adapter to the transmission.
6. Remove the adapter from the transmission (automatic shown).
7. Remove the seal between the transfer case and the adapter.
8. Remove the gasket from the adapter.

Installation Procedure





Note: Always use a new gasket and seal for the adapter. Do not use any type of sealant or adhesive in place of or with the gasket or the seal.

1. Install the new seal onto the transfer case.

Note: The transfer case adapter must be installed so that the adapter is evenly seated to the transmission before installing the retaining nuts.

2. Install the adapter to the transmission.

Caution: Refer to Fastener Caution (Fastener Caution).

3. Install the adapter mounting bolts to the transmission.

Tighten the mounting bolts to 50 Nm (36 lb ft).

Note: When installing the gasket to the adapter, make sure that the yellow printing on the gasket is facing toward the transfer case (away from the transmission). The locating tab on the gasket should always be pointing up.

4. Install the new gasket to the adapter.
5. Install the transfer case to the adapter. Refer to Transfer Case Assembly Replacement (Transfer Case Assembly Replacement).




6. Install the crossmember in the vehicle.

Tighten the mounting bolts to 95 Nm (70 lb ft).

7. Remove the transmission jack from the transmission.
8. Check the fluid level of the transfer case. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
9. Lower the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).