Removal Procedure
Important: Before the motor/encoder is removed, ensure that the motor/encoder is in the
neutral position.
- Raise the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.
- Remove the transfer case shield, if equipped. Refer to
Transfer Case Shield Replacement
in Frame and Underbody.
- Disconnect the motor/encoder electrical
connector (1).
- Remove the motor/encoder mounting bolts.
- Remove the motor/encoder assembly.
Important: When replacing the encoder rotary position sensor follow these additional steps.
The rotary position sensor is circular with 3 contacts on one side and is positioned
behind the motor/encoder gasket.
- Position the motor on a work bench.
- Release the 4 tabs that retain the motor/encoder
gasket and remove the gasket (1).
- Remove the snap ring and washer retaining the motor/encoder rotary position
sensor.
Important: Gently lift the rotary position sensor and wiring to disconnect it. The internal
wires go to a connector within the motor housing. This internal wire connector does
not have a locking tab and is easily disturbed.
- Lift the motor/encoder rotary position sensor (2) from the motor shaft.
- Disconnect the rotary position sensor (2) from the wiring harness.
Important: Look at the motor/encoder housing (1) where the rotary position sensor
was removed from. Take note of the "Hex" in the housing where the new
sensor will seat when properly installed.
Installation Procedure
Important: Provided the rotary position sensor was removed, follow steps to install the
sensor, otherwise proceed to installing the motor/encoder to the transfer case.
- Connect the wiring harness to the rotary position sensor.
- Gently insert a suitable tool along side the internal wires and press
down on the internal wire connector to insure the connector is fully installed.
- Properly align the keyway of the rotary position sensor with the motor/encoder
shaft as indicated by the center reference line shown in the graphic.
- Ensure that the hex on the rotary position
sensor (2) fits in the hex of the motor/encoder housing (3).
- Install the washer and snap ring retaining the motor/encoder rotary position
sensor.
- Install the washer and snap ring retaining the motor/encoder rotary position
sensor.
- Install the motor/encoder gasket (1).
Important: When performing this service procedure, make sure that the motor/encoder unit
is flat against the transfer case for proper installation.
- Install the motor/encoder to the transfer case.
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 motor/encoder mounting bolts to the transfer case.
Tighten
Tighten the bolts to 16 N·m (12 lb ft).
- Connect the motor/encoder electrical
connector (1).
- Install the transfer case shield, if equipped. Refer to
Transfer Case Shield Replacement
in Frame and Underbody.
- Lower the vehicle. Refer to
Lifting and Jacking the Vehicle
in General Information.