Transfer Case Replacement Auto Four Wheel Drive

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 propeller shaft. Refer to Front Propeller Shaft Replacement .
4. Remove the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement , to Two-Piece Propeller Shaft Replacement , or to Three-Piece Propeller Shaft Replacement in Propeller Shaft.



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



7. Remove the transfer case motor/encoder.

Support the transfer case with a jack.




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



10. 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: Refer to Fastener Notice in the Preface section.




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. Install the transfer case motor/encoder.
5. Install the electrical connectors and the wiring harness to the transfer case with the new straps.
6. Install the rear propeller shaft. Refer to One-Piece Propeller Shaft Replacement , to Two-Piece Propeller Shaft Replacement , or to Three-Piece Propeller Shaft Replacement in Propeller Shaft.
7. Remove the jack from the transfer case.
8. Install the front propeller shaft. Refer to Front Propeller Shaft Replacement .
9. Install the transfer case shield. Refer to Shield Replacement .

•	Inspect the transfer case lubricant level. Add oil as necessary. Refer to Capacities - Approximate Fluid .

•	Lower the vehicle.