Removal Procedure
- Remove the transfer case shield, if equipped. Refer to
Transfer Case Shield Replacement
.
- Remove the front propeller shaft. Refer to
Front Propeller Shaft Replacement
.
- Remove the rear propeller shaft. Refer to
Rear Propeller Shaft Replacement
.
- Remove the vent hose (2) from the transfer case fitting (1).
- Reposition the vent hose out of the way.
- Remove the harness inline to engine harness connector (1) clip from the
fuel feed and return pipe bracket.
- Disconnect the encoder motor electrical connector (7).
- Disconnect the speed sensor electrical connectors (3, 4, and 5).
- Remove the harness clips (6, 8) from the transfer case.
- Reposition the harness out of the way.
Important: Ensure that the transfer case is correctly secured to the transmission jack.
- Support the transfer case with a suitable transmission jack.
Important: When removing the transfer case from the transmission, do not remove the transmission mount or the transfer case adapter.
- Remove the transfer case adapter nuts.
- Remove the fuel feed and return pipe bracket.
- Separate the transfer case from the transmission by moving the transfer case straight back toward the rear of the vehicle.
- Rotate the transfer case so that the transfer case left side is pointing down.
- With an assistant, move the transfer case rearward as far as possible. Position the front of the transfer case down between cross members.
- Remove the transfer case.
Installation Procedure
- With an assistant, position the transfer case so that the transfer case is between the cross members.
- Raise the transfer case into position.
- Rotate the transfer case so that the transfer case aligns with the transfer case adapter.
- Install the transfer case.
- Install the fuel feed and return pipe bracket.
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.
- Install the transfer case adapter nuts.
Tighten
Tighten the nuts to 50 N·m (37 lb ft).
- Remove the transmission jack from the transfer case.
- Position the harness to the transfer case.
- Install the harness clips (6, 8) to the transfer case.
- Connect the speed sensor electrical connectors (3, 4, and 5).
- Connect the encoder motor electrical connector (7).
- Install the harness inline to engine harness connector (1) clip to the fuel feed and return pipe bracket.
- Position the vent hose to the transfer case.
- Install the vent hose (2) to the transfer case fitting (1).
- Install the rear propeller shaft. Refer to
Rear Propeller Shaft Replacement
.
- Install the front propeller shaft. Refer to
Front Propeller Shaft Replacement
.
- Install the transfer case shield, if equipped. Refer to
Transfer Case Shield Replacement
.