Aspen 2007, Durango 2006-2007

Transfer Case Removal & Installation

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NV144



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Shift transfer case into AWD.
  4.  
  5. Raise vehicle.
  6.  
  7. Drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shafts for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove the transfer case skid plate, if equipped.
  14.  
  15. Disconnect front and rear propeller shafts at transfer case.
  16.  
  17. Disconnect transfer case shift motor and mode sensor wire connectors.
  18.  
  19. Disconnect transfer case vent hose.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case onto the transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 20-25 ft. lbs. (27-34 Nm) torque.
  10.  
  11. Connect the vent hose.
  12.  
  13. Connect the shift motor and mode sensor assembly wiring connector. Secure wire harness to clips on transfer case.
  14.  
  15. Align and connect the propeller shafts.
  16.  
  17. Fill transfer case with correct fluid.
  18.  
  19. Install skid plate, if equipped.
  20.  
  21. Remove transmission jack and support stand.
  22.  
  23. Lower vehicle and verify transfer case shift operation.
  24.  

NV244



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Shift transfer case into AWD.
  4.  
  5. Raise vehicle.
  6.  
  7. Drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shafts for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove the transfer case skid plate, if equipped.
  14.  
  15. Disconnect front and rear propeller shafts at transfer case.
  16.  
  17. Disconnect transfer case shift motor and mode sensor wire connectors.
  18.  
  19. Disconnect transfer case vent hose.
  20.  
  21. Support transfer case with transmission jack.
  22.  
  23. Secure transfer case to jack with chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Pull transfer case and jack rearward to disengage transfer case.
  28.  
  29. Remove transfer case from under vehicle.
  30.  

To install:

  1. Mount transfer case on a transmission jack.
  2.  
  3. Secure transfer case to jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align transfer case and transmission shafts and install transfer case onto the transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 20-25 ft. lbs. (27-34 Nm) torque.
  10.  
  11. Connect the vent hose.
  12.  
  13. Connect the shift motor and mode sensor assembly wiring connector. Secure wire harness to clips on transfer case.
  14.  
  15. Align and connect the propeller shafts.
  16.  
  17. Fill transfer case with correct fluid.
  18.  
  19. Install skid plate, if equipped.
  20.  
  21. Remove transmission jack and support stand.
  22.  
  23. Lower vehicle and verify transfer case shift operation.
  24.  

 
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