Installation

INSTALLATION




1. Support transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position the transfer case under the vehicle and align the input shaft with the transmission output shaft.
4. Move the transfer case and jack forward to engage transfer case to the transmission.
5. Install the nuts and bolts to attach transfer case to transmission. Tighten the 120 mm bolts to 25 Nm (18 ft.lbs.), the 30 mm bolts to 27 Nm (20 ft.lbs.), and the nuts to 20 Nm (15 ft.lbs.)
6. Raise the transmission and transfer case into their normal position.
7. Fill (1, 2) the transfer case with the appropriate fluid.
8. Install the transfer case dampner.




9. Install the transmission mount assembly to the transfer case and install the bolts (3) to hold the transmission mount assembly (2) to the transfer case (1), 3.5L engine. Tighten the bolts to 55 Nm (41 ft.lbs.).




10. Install the transmission mount to the transfer case and install the bolts (2) to hold the transmission mount (1) to the transfer case, 5.7L engine. Tighten the bolts to 68 Nm (50 ft.lbs.).




11. Install the bolts (2) to hold the transmission crossmember (1) to the transmission mount (3). Tighten the bolts to 65 Nm (48 ft.lbs.).
12. Install the bolts to hold the transmission crossmember to the frame.Tighten the bolts to 68 Nm (50 ft.lbs.).
13. Install the front and rear propeller shafts to the transfer case.