Dakota 2006-2007

Transfer Case Removal & Installation

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NV233



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

    Click image to see an enlarged view

    Fig. Typical transfer case mounting

  30.  

To install:

  1. Mount the transfer case on a transmission jack.
  2.  
  3. Secure the transfer case to the jack with chains.
  4.  
  5. Position transfer case under vehicle.
  6.  
  7. Align the transfer case and transmission shafts and install the transfer case onto the transmission.
  8.  
  9. Install and tighten the transfer case attaching nuts to 27-34 Nm (20-25 ft. lbs.).
  10.  
  11. Connect the vent hose.
  12.  
  13. Connect the shift motor and mode sensor wiring connectors. Secure the wire harness to clips on the transfer case.
  14.  
  15. Align and connect the propeller shafts.
  16.  
  17. Fill the transfer case with the correct fluid.
  18.  
  19. Install the rear crossmember and skid plate, if equipped. Tighten the crossmember bolts to 41 Nm (30 ft. lbs.).
  20.  
  21. Remove the transmission jack and support stand.
  22.  
  23. Lower the 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. Disconnect front and rear propeller shafts at transfer case.
  12.  
  13. Support transmission with jack stand.
  14.  
  15. Remove rear crossmember and skid plate, if equipped.
  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 from the transmission adapter housing and output shaft.
  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 27-34 Nm (20-25 ft. lbs.). Connect the vent hose.
  10.  
  11. Connect the shift motor and mode sensor wiring connectors. Secure wire harness to clips on transfer case.
  12.  
  13. Align and connect the propeller shafts.
  14.  
  15. Fill transfer case with correct fluid.
  16.  
  17. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 41 Nm (30 ft. lbs.).
  18.  
  19. Remove transmission jack and support stand.
  20.  
  21. Lower vehicle and verify transfer case shift operation.
  22.  

 
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