Transfer Case Replacement With Automatic Transmission

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the transfer case shield. Refer to Shield Replacement .
3. Remove the front and rear propeller shafts. Refer to Front Propeller Shaft Replacement , or to One-Piece Propeller Shaft Replacement or to Two-Piece Propeller Shaft Replacement .
4. Remove the vent hose from the transfer case vent.
5. Disconnect the electrical connectors from the three speed sensors.
6. Disconnect the electrical connector from the encoder/motor.
7. Remove the wiring harness from the transfer case.
8. Support the transfer case with a jack.



9. Remove the bolts securing the transfer case to the transmission.
10. Remove the transfer case from the transmission.



11. Remove and discard the gasket.

1. Install a new gasket to the transmission. Apply a thin coat of clear RTV in order to hold the gasket in place.



2. Install the transfer case to the transmission.

Notice: Refer to Fastener Notice in the Preface section.




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

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

in General Information.

4. Remove the jack from the transfer case.
5. Connect the electrical connector to the three speed sensors.
6. Connect the electrical connector to the encoder/motor.
7. Install the vent hose to the transfer case vent.
8. Install the front and rear propeller shafts. Refer to Front Propeller Shaft Replacement , or to One-Piece Propeller Shaft Replacement or to Two-Piece Propeller Shaft Replacement .
9. Install the transfer case shield. Refer toShield Replacement .

•	Check the transfer case oil level. Add oil as necessary. Refer to Approximate Fluid Capacities .

•	Lower the vehicle.

10. Inspect the transfer case for normal operation.