PRE-RELEASE
Transfer Case Replacement
| Transfer Case Replacement |
| Removal Procedure |
| 1. |
Remove the propeller shaft. Refer to
Propeller Shaft Replacement
.
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| 2. |
Drain the oil from the transmission . Refer to
Transmission Fluid Replacement
.
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| 3. |
Remove the right wheel driveshaft. Refer to
Front Wheel Drive Shaft Replacement
.
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| 4. |
Remove the transmission rear mount bracket. Refer to
Transmission Rear Mount Replacement (AWD)
Transmission Rear Mount Replacement (FWD)
.
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| 5. |
Remove the drivetrain and front suspension frame. Refer to
Drivetrain and Front Suspension Frame Replacement
.
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| 6. |
Remove the transfer case vent hose strap (1), bolt (3), and hose (2).
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| 7. |
Remove the transfer case support bracket-to-transfer case bolts (2).
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| 8. |
Remove the transfer case support bracket-to-engine bolts (3).
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| 9. |
Remove the support bracket (1).
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| 10. |
Support the transfer case with a suitable jack, and secure with suitable straps.
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| 11. |
Remove the transfer case-to-transmission center bolt (3). The center bolt is accessed through the opening in the center of the transfer case.
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| 12. |
Remove the remaining transfer case-to-transmission bolts (2).
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| 13. |
Separate the transfer case (1) from the transmission and remove the transfer case.
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| Installation Procedure |
| 1. |
Clean the contact surfaces between the transfer case and the transmission. Install a new transfer case-to-transmission O-ring (1).
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| 2. |
Support the transfer case with a suitable jack, and secure with suitable straps.
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| 3. |
Raise and align the transfer case in the correct position in relation to the transmission.
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| 4. |
Install the transfer case (1) to the transmission.
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| 5. |
Refer to
Fastener Caution
.
Install the transfer case-to-transmission bolts (2). |
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| 6. |
Install the transfer case-to-transmission center bolt (3). The center bolt is accessed through the opening in the center of the transfer case.
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| 7. |
Tighten the bolts to
110 Nm (81 lb ft)
.
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| 8. |
Install the support bracket (1).
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| 9. |
Install the transfer case support bracket-to-transfer case bolts (2)
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| 10. |
Install the transfer case support bracket-to-engine bolts (3)
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| 11. |
Install the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.
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| 11.1. |
Tighten the support bracket-to-transfer case bolts (2) to
5 Nm (44 lb in)
.
|
| 11.2. |
Tighten the support bracket-to-engine bolts (3) to
60 Nm (44 lb in)
.
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| 11.3. |
Tighten the support bracket-to-fastener bolts to
60 Nm (44 lb in)
.
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| 12. |
Install the transmission rear mount bracket.
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| 13. |
Install the transfer case vent hose (2), strap (1), and bolt (3).
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| 14. |
Tighten the transfer case breather hose bolt, if equipped, to
22 Nm (17 lb ft)
.
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| 15. |
Install the drivetrain and front suspension frame. Refer to
Transmission Rear Mount Replacement (AWD)
Transmission Rear Mount Replacement (FWD)
.
|
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| 16. |
Install the right driveshaft. Refer to
Front Wheel Drive Shaft Replacement
.
|
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| 17. |
Install the propeller shaft. Refer to
Propeller Shaft Replacement
.
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| 18. |
Fill the transmission with oil. Refer to
Transmission Fluid Replacement
.
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| 19. |
Fill with transfer case oil. Refer to
Approximate Fluid Capacities
.
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