Chrysler Full-Size Trucks 1989-1996 Repair Guide

Transfer Case

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REMOVAL & INSTALLATION



Pick-Up and Ramcharger

See Figures 1, 2 and 3

  1. Raise and support the truck.
  2.  
  3. Remove the skid plate, if equipped.
  4.  
  5. Drain the transfer case by removing the bottom bolt from the front output rear cover.
  6.  
  7. Disconnect the speedometer cable.
  8.  
  9. Disconnect the front and rear output shafts. Suspend these from a convenient location; do not allow them to hang free.
  10.  
  11. Disconnect the shift rods at the transfer case.
  12.  
  13. Support the transfer case.
  14.  
  15. Remove the adapter-to-transfer case mounting bolts and move the transfer case rearward to disengage the front input splines.
  16.  
  17. Lower and remove the transfer case.
  18.  
  19. Installation is the reverse of removal. Adjust the linkage.
  20.  

Dakota

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support safely.
  4.  
  5. Remove the skid plates, if equipped. Drain the transfer case fluid.
  6.  
  7. Disconnect the distance sensor, if equipped and disconnect the speedometer cable from the transfer case.
  8.  
  9. Matchmark and remove the driveshafts.
  10.  
  11. Disconnect the Power Take-Off (PTO), if equipped.
  12.  
  13. Disconnect the linkage, electrical connectors and vacuum lines from the transfer case. Using a suitable jack, support the transfer case and remove the crossmember.
  14.  
  15. Unbolt the transfer case from the transmission and slide it backward to remove it from the vehicle.
  16.  
  17. The installation is the reverse of the removal procedure. Tighten the transfer case to transmission case nuts to 26 ft. lbs. (35 Nm). Fill the transfer case with ATF+3®II.
  18.  



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Fig. Fig. 1: Unbolt the skid plate from the transfer case, if equipped



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Fig. Fig. 2: Once the transfer case is installed, remove the plug with a suitable wrench or ratchet and socket



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Fig. Fig. 3: Always fill the transfer case with the specified lubricant for your vehicle

 
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