For 1990-2009 cars only
Removal Procedure
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General information.
- Remove the transfer case shield from the crossmember. Refer to Transfer Case Shield Replacement .
- Remove the brace from the transfer case to the engine assembly.
- Drain the transfer case of fluid. Refer to Transfer Case Fluid Replacement .
- Remove the rear propeller shaft from the vehicle.
- Remove the front propeller shaft from the vehicle. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Remove the motor/encoder electrical connector.
- Remove the electrical wiring harness from the transfer case.
- Remove the vent hose from the transfer case.
- Support the transmission with a suitable jack stand.
- Remove the transmission mount retaining bolts from the transmission support.
- Remove the transmission support mounting bolts from the frame.
- Raise the transmission assembly in order to remove the transmission support from the vehicle.
- Remove the transmission support assembly.
- Remove the transmission mount from the transfer case adapter (automatic transmission only).
- Remove the transfer case to the transfer case adapter retaining nuts.
- Remove the transfer case from the transfer case adapter straight back toward the rear of the vehicle.
- Lower the front of the transfer case.
- Raise the rear of the transfer case so that it above the torsion bar bracket.
- In a downward motion, remove the transfer case from the vehicle.
- Remove the transfer case gasket.
| • | For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement in Propeller Shaft. |
| • | For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft. |
Important: The following service procedure should be performed with the aid of another technician.
Important: If during the removal of the transfer case the gasket becomes damaged, do not reuse the gasket. Replace the damaged gasket with a new one. DO NOT use any type of sealant in place of the gasket.
Installation Procedure
- Install a new gasket to the transfer case adapter with the tab facing upward.
- Install the transfer case to the transfer case adapter.
- Install the transfer case retaining nuts on the transfer case mounting studs.
- Install the transmission mount to the transfer case adapter.
- Install the transmission support assembly.
- Install the transmission support mounting bolts.
- Install the transmission mount retaining nuts.
- Remove the transmission jack from the transmission.
- Install the motor/encoder electrical connector.
- Install the electrical wiring harness to the transfer case.
- Install the vent hose to the transfer case.
- Install the rear propeller shaft in the vehicle.
- Install the front propeller shaft in the vehicle. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Install the engine brace from the transfer case to the engine assembly (left side shown).
- Fill the transfer case with the approved fluid. Refer to Transfer Case Fluid Replacement .
- Install the transfer case shield to the vehicle. Refer to Transfer Case Shield Replacement .
- Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Important: The following service procedure should be performed with the aid of another technician.
Tighten
Tighten the transfer case retaining nuts to 55 N·m (39 lb ft).
Tighten
Tighten the transmission mount bolts to 47 N·m (35 lb ft).
Tighten
Tighten the transmission support bolts to 70 N·m (50 lb ft).
Tighten
Tighten the transmission mount retaining nuts and bolts to 46 N·m
(35 lb ft).
| • | For vehicles equipped with the one piece propeller shaft, refer to One-Piece Propeller Shaft Replacement in Propeller Shaft. |
| • | For vehicles equipped with the two piece propeller shaft, refer to Two-Piece Propeller Shaft Replacement in Propeller Shaft. |
Tighten
Tighten the engine brace bolts to 50 N·m (37 lb ft).
