Transfer Case Assembly

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Place the transmission in Neutral.
3. Drain the transfer case.
4. Remove or disconnect the following:
   • Negative battery cable
   • Skid plate
   • Damper, if equipped
   • Wire connector from rear of the transfer case, on electronic-shift models
   • Front driveshaft from the axle input yoke
   • Clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft, if equipped
   • Rear driveshaft from the transfer case output shaft yoke
   • Speedometer driven gear from the transfer case rear cover, if equipped
   • Electrical plug from the Vehicle Speed Sensor (VSS), if equipped
   • Vent hose
5. On manual-shift models, perform the following:
   1. Remove the shift lever retaining nut and remove the lever.
   2. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
6. If equipped, remove the heat shield from the transfer case.
7. Support the transfer case with a transmission jack.
8. Install or connect the following:
   • 5 bolts (6 bolts on the AWD transfer case) retaining the transfer case to the transmission and the extension housing
   • Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle.
   • Gasket from between the transfer case and extension housing

   To install:

   Fig. 1: Transfer case-to-extension bolt torque sequence

9. Install or connect the following:
   • Heat shield onto the transfer case, if equipped
   • New gasket between the transfer case and adapter
10. Align the output shaft with the splined transfer case input shaft.
    • Slide the transfer case forward on to the transmission output shaft and onto the dowel pin. Torque the bolts to 25–35 ft. lbs. (34–47 Nm).
    • Shifter to the extension housing
    • Vent tube
    • VSS plug, if equipped
    • Speedomter driven gear to the rear cover, if equipped
    • Driveshaft front boot, if equipped
    • Front driveshaft to the axle input yoke
    • Wire connector to the rear of the transfer case
    • Damper, if equipped
    • Skid plate
    • Negative battery cable
11. Fill the transfer case to the proper level.
12. Start the vehicle and check for leaks, repair if necessary.

    Fig. 2: Exploded view of the 13-54 mechanical shift transfer case-to-transmission mounting

    Fig. 3: Exploded view of the 13-54 electronic shift transfer case-to-transmission mounting — 44-05 model is similar