Special Tools

For equivalent regional tools, refer to Special Tools.

1. Install the transfer case input shaft bearing retainer seal (2), using  DT 49094 drift and the input shaft (1).
2. Install the input shaft.



3. Install the transfer case input shaft bearing retainer seal (1), using  DT 49093 drift .



4. Clean all of the sealing surface of the transfer case housing and rear extension housing (2).
5. Clean the transfer case rear extension bolt holes. Thread repair tool may be used to clean the threads of old threadlocking material.
6. Spray thread cleaner into hole. Refer to Adhesives, Fluids, Lubricants, and Sealers for recommended thread cleaner.

Warning: Wear safety glasses when using compressed air in order to prevent eye injury.

7. Clean the transfer case rear extension bolt holes with compressed air.
8. Place a bead of sealant onto the sealing surface of the housing. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended sealant.
9. Place the transfer case rear extension housing onto the transfer case housing.

Note: Use NEW bolts.

10. Apply threadlock to the threads of the transfer case rear extension bolts (1). Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended threadlock material.

Caution: Refer to Fastener Caution in the Preface section.

11. Install the NEW 9 transfer case rear extension bolts (1).

11.1.

Tighten the 9 transfer case rear extension bolts (1) a first pass to 20 N·m (15 lb ft).

11.2.

Tighten the 9 transfer case rear extension bolts (1) a second pass to 30 degrees.