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Transfer Case Replacement

Transfer Case Replacement

Removal Procedure


1. Remove the propeller shaft. Refer to Propeller Shaft Replacement .

2. Drain the oil from the transmission . Refer to Transmission Fluid Replacement .

3. Remove the right wheel driveshaft. Refer to Front Wheel Drive Shaft Replacement .

4. Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement (AWD) Transmission Rear Mount Replacement (FWD) .

5. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement .

6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).


7. Remove the transfer case support bracket-to-transfer case bolts (2).


8. Remove the transfer case support bracket-to-engine bolts (3).

9. Remove the support bracket (1).

10. Support the transfer case with a suitable jack, and secure with suitable straps.

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.


12. Remove the remaining transfer case-to-transmission bolts (2).


13. Separate the transfer case (1) from the transmission and remove the transfer case.


Installation Procedure


1. Clean the contact surfaces between the transfer case and the transmission. Install a new transfer case-to-transmission O-ring (1).


2. Support the transfer case with a suitable jack, and secure with suitable straps.


3. Raise and align the transfer case in the correct position in relation to the transmission.

4. Install the transfer case (1) to the transmission.

5. Refer to Fastener Caution .

Install the transfer case-to-transmission bolts (2).

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.


7. Tighten the bolts to 110 Nm (81 lb ft) .

8. Install the support bracket (1).


9. Install the transfer case support bracket-to-transfer case bolts (2)

10. Install the transfer case support bracket-to-engine bolts (3)

11. Install the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.

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) .

11.3. Tighten the support bracket-to-fastener bolts to 60 Nm (44 lb in) .

12. Install the transmission rear mount bracket.

13. Install the transfer case vent hose (2), strap (1), and bolt (3).


14. Tighten the transfer case breather hose bolt, if equipped, to 22 Nm (17 lb ft) .

15. Install the drivetrain and front suspension frame. Refer to Transmission Rear Mount Replacement (AWD) Transmission Rear Mount Replacement (FWD) .

16. Install the right driveshaft. Refer to Front Wheel Drive Shaft Replacement .

17. Install the propeller shaft. Refer to Propeller Shaft Replacement .

18. Fill the transmission with oil. Refer to Transmission Fluid Replacement .

19. Fill with transfer case oil. Refer to Approximate Fluid Capacities .