Transfer Case Assembly

Removal & Installation

To Remove:

1. Put vehicle in NEUTRAL then raise and safely support the vehicle.
2. Remove the skid plate.
3. If equipped, remove the damper.
4. Disconnect the transfer case harness connector.
5. If disassembly of the transfer case is necessary, remove the drain plug and drain the fluid. Once all of the fluid has drained, install the plug and torque to 18 ft-lb (24 Nm).
6. Disconnect the heated oxygen sensor connector and move it to the side.

   CAUTION
   Make alignment marks on the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

   CAUTION
   Make sure to first disconnect the front driveshaft from the transfer case for this procedure. Failure to do this can cause the weight of the driveshaft to pinch the boot between the shaft and the boot can, which can cause the boot to tear.

7. Disconnect the front driveshaft from the transfer case.

   NOTE: Make alignment marks on the front flange on the rear driveshaft and the flange on the transfer case.

8. Remove the rear driveshaft.

   CAUTION
   Make sure to use safety straps to secure the transfer case to the jack.

9. Place an appropriate jack under the transfer case.
10. Remove the transfer case.

To Install:

NOTE: Make sure to use a new gasket when installing the transfer case.

NOTE: Torque the bolts that fasten the transfer case to the extension housing in a clockwise direction starting with the upper left-hand bolt.

NOTE: During installation of the front driveshaft, always connect it to the axle first, then to the transfer case.

NOTE: The front driveshaft should be installed with new washers and bolts and the rear driveshaft with new bolts. In the event new bolts are unavailable, use threadlock and sealer to coat the threads of the existing bolts.

NOTE: When installing both the front and rear driveshafts, use the alignment marks made during removal.

1. Install the transfer case. Torque to 40 ft-lb (54 Nm).
2. Remove the jack from under the transfer case.
3. Install the rear driveshaft.
4. Connect the front driveshaft to the transfer case. Torque to 22 ft-lb (30 Nm).
5. If needed, fill the transfer case with the correct type and amount of fluid.
6. Connect the transfer case harness connector.
7. If equipped, install the damper. Torque to 30 ft-lb (40 Nm).
8. Install the skid plate. Torque to 18 ft-lb (24 Nm).
9. Safely lower the vehicle.