Transfer Case Assembly Replacement

Removal Procedure





1. Raise the vehicle. Refer to Vehicle Lifting.
2. Remove the transfer case shield. Refer to Shield Replacement.
3. Remove the front propeller shaft. Refer to Propeller Shaft Replacement - Front or Propeller Shaft Replacement - Two Piece in Drive/Propeller Shafts, Bearings & Joints.
4. Remove the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Drive/Propeller Shafts, Bearings & Joints.
5. Disconnect the vehicle speed sensor electrical connector.
6. Disconnect the wiring harness from the transfer case.





7. Remove the transfer case motor/encoder. Support the transfer case with a jack.





8. Remove the bolts
securing the transfer case to the transmission adapter.
9. Remove the gasket.





10. Discard the gasket.

Installation Procedure





1. Install a new gasket to the transmission. Use a gasket sealer in order to hold the gasket in place.





2. Install the transfer case to the transmission adapter.





Notice: Refer to Fastener Notice in Service Precautions

3. Install the bolts that secure the transfer case to the transmission adapter.
^ Tighten the bolts to 45 Nm (33 ft. lbs.).





4. Install the transfer case motor/encoder.
5. Remove the jack from the transfer case.
6. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
7. Install the rear propeller shaft. Refer to Propeller Shaft Replacement - Rear in Drive/Propeller Shafts, Bearings & Joints.
8. Install the front propeller shaft. Refer to Propeller Shaft Replacement - Front in Drive/Propeller Shafts, Bearings & Joints.
9. Check the transfer case lubricant level. Add oil as necessary. Refer to Capacities - Approximate Fluid.
10. Install the transfer case shield. Refer to Shield Replacement
11. Lower the vehicle.