REMOVAL & INSTALLATION
See Figures 1 and 2
- Disconnect the negative battery cable.
- Raise the vehicle and support it safely with jackstands.
- Place a suitable drain pan under the transfer case and drain plug.
- Remove the transfer case drain plug and drain the fluid from the assembly.
- Tag and disconnect the transfer case control harness from the side of the assembly.
Mark the driveshaft and flanges so they can be reassembled in their original position.
- Disconnect the front driveshaft from the shaft flange.
- Remove the bolts that connect the inboard halfshaft flange to the axle shaft. Wire the halfshafts to the body, maintaining a level position.
- Place a suitable drain pan below the transfer case where it connects to the rear driveshaft. Loosen and remove the retainer bolts securing the rear driveshaft to the rear axle. Separate the driveshaft from the transfer case and place aside.
- Support the assembly with a transmission jack or equivalent, then remove the locknuts and bolts that connect the transfer case to the extension housing.
- Lower the hoist and slide the transfer case away from the extension housing. Remove all gasket material from the mating surfaces.
- Using a new extension housing gasket, position the gasket between the transfer case and extension housing.
- Raise the transfer case assembly into position with a hoist or equivalent and insert the retainer bolts. Apply Loctite® and tighten the bolts to 25-34 ft. lbs. (34-46 Nm).
- Install the rear driveshaft and tighten the retainer bolts to 61-87 ft. lbs. (83-118 Nm).
- Position and align the inboard halfshaft flange with the flange. Apply Loctite® and torque the bolts to 26 ft. lbs. (35 Nm).
- Install the front tire assemblies and torque the lug nuts to 100 ft. lbs. (136 Nm).
- Install the front driveshaft to the original position, install the bolts and tighten to 22-30 ft. lbs. (30-40 Nm).
- Connect the transfer case electrical harness.
- Lower the transfer case jack. Remove the jackstands and lower the vehicle.
- Connect the negative battery cable.
- Make sure the transfer case drain plug is tightened to 10-20 ft. lbs. (14-27 Nm). With the vehicle on level ground, fill the transfer case through the fill hole on the side of the case with Mercon® type fluid until the level is 1 / 4 in. (6.35mm) below the fill plug hole.
- Connect the negative battery cable. Check for proper vehicle operation.