Valve Body: Service and Repair

Valve Body Underview:

Removal

1. Remove both oil pans and the transmission fluid filter.
2. Disconnect solenoid valve electrical connectors 1 through 5.
3. Remove transfer case valve body mounting bolts using socket tool No. 24-5-180 or equivalent.
4. Remove transfer case valve body, then remove servo piston cover.
5. Remove main body valve body mounting bolts using socket tool No. 24-5-180 or equivalent.
6. Carefully lift off main valve body with gasket, pulling overrun valve connecting lever off of pawl. Overrun valve should remain in main valve body.
7. Separate transfer plate from valve body and remove gasket.

Check Ball Locations:

Installation

1. Mount gasket and transfer plate on main valve body. Center gasket with alignment tools No. 24-5-140 or equivalent.
2. Place two check balls in main case. Secure check balls with petroleum jelly.
3. Secure gasket with petroleum jelly and place main valve body on main case. Attach connecting lever on overrun valve and operating lever.
4. Install main valve body mounting bolts and tighten crosswise.
5. Secure lockplate, then install servo piston cover.
6. Place check ball in transfer case. Secure with petroleum jelly.

Gasket Location:

7. Ensure check ball is installed at position (1), Mount gasket (2) with oval opening (3) at check ball. Mount transfer plate (4) and second gasket (5).
8. Place transfer case valve body on transfer case and install mounting bolts. Tighten bolts in a crossing pattern.
9. Connect solenoid valve plugs and install transmission fluid pans.