Chrysler Full-Size Trucks 1997-2000 Repair Guide

Transfer Case Assembly

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REMOVAL & INSTALLATION



  1. Disconnect the battery negative cable.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. Drain the transfer case lubricant.
  6.  
  7. Matchmark the front and rear drive shafts on yokes or flanges so that they can be reinstalled in the original positions.
  8.  
  9. Remove the skidplate, if fitted, and rear frame crossmember if needed for clearance.
  10.  
  11. Disconnect both driveshafts from the transfer case.
  12.  
  13. Disconnect the PTO, if fitted.
  14.  
  15. Disconnect the shift linkage.
  16.  
  17. Disconnect the vent hose and any switch connectors fitted to the case.
  18.  
  19. Disconnect the wires of the vehicle speed sensor, if fitted.
  20.  
  21. Support the case with a transmission jack. Secure the transfer case to the jack with chains.
  22.  
  23. Remove the nuts securing the transfer case to the transmission.
  24.  
  25. Pull the assembly back towards the rear of the vehicle to disengage it.
  26.  
  27. Remove the transfer case from the vehicle.
  28.  

To install:

  1. Reverse the removal procedure.
  2.  
  3. Tighten the transfer case-to-transmission nuts. Tighten 5 / 16 in. nuts to 22-30 ft. lbs. Tighten 3 / 8 in. nuts to 30 -35 ft. lbs. (41-47 Nm).
  4.  
  5. Be sure to add the proper amount and grade of fluid.
  6.  



Click image to see an enlarged view

Fig. Transfer case driveline-typical



Click image to see an enlarged view

Fig. Transfer case mounting arrangement-typical



Click image to see an enlarged view

Fig. Transfer case shift assembly-typical

 
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