Commander 2006-2007

Transfer Case Removal & Installation

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NV140



  1. Raise and safely support the vehicle.
  2.  
  3. Remove transfer case drain plug and drain the transfer case lubricant.
    NOTE
    Do not allow drive shafts to hang at attached end. Damage to joint can result.

  4.  
  5. Remove the front and rear driveshafts.
  6.  
  7. Support the transmission with jack stand.
  8.  
  9. Remove rear crossmember and skid plate, if equipped.
  10.  
  11. Disconnect transfer case vent hose.
  12.  
  13. Support transfer case with transmission jack and secure with chains.
  14.  
  15. Remove the nuts attaching transfer case to transmission.
  16.  
  17. Pull transfer case and jack rearward to disengage transfer case.
  18.  
  19. Remove transfer case from under vehicle.

    Click image to see an enlarged view

    Fig. Remove the vent hose (4) and mounting nuts (2) to remove the transfer case (1) from the transmission (3)-NV140 Transfer Case

  20.  

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 26 ft. lbs .(35 Nm).
  10.  
  11. Connect front and rear drive shafts. Torque the front driveshaft-to-transfer case bolts to 24 ft. lbs. (32 Nm). Torque the rear driveshaft-to-transfer case bolts to 80 ft. lbs. (108 Nm).
  12.  
  13. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  14.  
  15. Install the transfer case fill plug. Tighten the plug to 15-25 ft. lbs. (20-34 Nm).
  16.  
  17. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  18.  
  19. Remove transmission jack and support stand.
  20.  
  21. Lower vehicle and verify transfer case shift operation.
  22.  

NV245



  1. Shift the transfer case into NEUTRAL.
  2.  
  3. Raise and safely support the vehicle.
  4.  
  5. Remove the transfer case drain plug and drain transfer case lubricant.
  6.  
  7. Support the transmission with suitable jack stand.
  8.  
  9. Remove rear crossmember and skid plate, if equipped.
  10.  
  11. Disconnect front driveshaft from transfer case at companion flange. Remove rear driveshaft from vehicle.
    NOTE
    Do not allow driveshafts to hang at attached end. Damage to the joint can result.

  12.  
  13. Disconnect the transfer case shift motor and mode sensor connector.
  14.  
  15. Disconnect the transfer case vent hose.
  16.  
  17. Support the transfer case with a suitable transmission jack.
  18.  
  19. Secure the transfer case to the jack with chains.
  20.  
  21. Remove the mounting nuts attaching transfer case to transmission.
  22.  
  23. Pull the transfer case and jack rearward to disengage transfer case.
  24.  
  25. Remove the transfer case from under the vehicle.
  26.  

To install:

  1. Mount the transfer case on a transmission jack.
  2.  
  3. Secure the transfer case to jack with chains.
  4.  
  5. Position the transfer case under vehicle.
  6.  
  7. Align the transfer case and transmission shafts and install transfer case onto transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm).
  10.  
  11. Connect the transfer case vent hose to the transfer case.
  12.  
  13. Install the rear crossmember and skid plate, if equipped.
  14.  
  15. Remove the transmission jack and support stand.
  16.  
  17. Connect the front and rear driveshafts. Torque the front driveshaft-to-transfer case bolts to 24 ft. lbs. (32 Nm). Torque the rear driveshaft-to-transfer case bolts to 80 ft. lbs. (108 Nm).
  18.  
  19. Fill the transfer case with appropriate fluid to the correct level.
  20.  
  21. Install the transfer case fill plug and tighten to 15-25 ft. lbs. (20-34 Nm).
  22.  
  23. Connect the shift motor and mode sensor wiring connector.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

 
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