Transfer Case Replacement Manual Four Wheel Drive

1. Raise the vehicle.
2. Remove the front propeller shaft.
3. Remove the rear propeller shaft.



4. Disconnect the vehicle speed sensor electrical connector.
5. Disconnect the wiring harness from the transfer case.



6. Disconnect the transfer case shift cable at the transfer case.

Support the transfer case with a jack.




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



9. Discard the gasket.

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: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

3. Install the bolts that secure the transfer case to the transmission adapter.

Tighten
Tighten the bolts to 45 N·m (33 lb ft).

4. Remove the jack from the transfer case.
5. Install the transfer case shift linkage at the transfer case.
6. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
7. Install the front propeller shaft.
8. Install the rear propeller shaft.
9. Check the transfer case lubricant level. Add oil as necessary.
10. Lower the vehicle.