Removal Procedure
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General information.
- Remove the transfer case shield. Refer to Transfer Case Shield Replacement .
- Remove the rear propeller shaft.
- Remove the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Drain the transfer case of fluid. Refer to Transfer Case Fluid Replacement .
- Remove the motor/encoder electrical connector.
- Remove the transfer case electrical wiring harness.
- Remove the transfer case vent hose.
- Support the transmission with a suitable jack stand.
- Remove the transmission mount retaining bolts.
- Remove the transmission support assembly. Refer to Transmission Support Replacement in Frame and Underbody.
- Remove the transmission mount from the transfer case adapter (automatic transmission only).
- Remove the transfer case 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 the new gasket to the transfer case (tab facing upward).
- Install the transfer case assembly.
- Install the transmission mount assembly.
- Install the transmission support assembly. Refer to Transmission Support Replacement in Frame and Underbody.
- Install the transmission mount retaining nuts.
- Remove the transmission jack from the transmission.
- Install the motor/encoder electrical connector.
- Install the motor/encoder electrical wiring harness.
- Install the transfer case vent hose.
- Install the rear propeller shaft.
- Install the front propeller shaft. Refer to Front Propeller Shaft Replacement in Propeller Shaft.
- Fill the transfer case with the approved fluid. Refer to Transfer Case Fluid Replacement .
- Install the transfer case shield. Refer to Transfer Case Shield Replacement .
- Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
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.
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 55 N·m (40 lb ft).
Tighten
Tighten the transmission mount retaining nuts to 40 N·m
(30 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. |
