Liberty, Wrangler 2006-2007

Transfer Case Removal & Installation

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NV231



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Drain transfer case lubricant.
  8.  
  9. Mark front and rear propeller shaft yokes for alignment reference.
  10.  
  11. Support transmission with jack stand.
  12.  
  13. Remove rear crossmember, or skid plate.
  14.  
  15. Disconnect front/rear propeller shafts at transfer case.
  16.  
  17. Disconnect vehicle speed sensor wires.
  18.  
  19. Disconnect transfer case linkage rod from range lever.
  20.  
  21. Disconnect transfer case vent hose and indicator switch harness, if necessary.
  22.  
  23. Support transfer case with transmission jack.
  24.  
  25. Secure transfer case to jack with chains.
  26.  
  27. Remove nuts attaching transfer case to transmission.
  28.  
  29. Pull transfer case and jack rearward to disengage transfer case.
  30.  
  31. Remove transfer case from under vehicle.
  32.  

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 on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm) torque.
  10.  
  11. Connect vehicle speed sensor wires, and vent hose.
  12.  
  13. Connect indicator switch harness to transfer case switch, if necessary. Secure wire harness to clips on transfer case.
  14.  
  15. Align and connect propeller shafts.
  16.  
  17. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  18.  
  19. Install rear crossmember, or skid plate. Tighten crossmember bolts to 30 ft. lbs. (41 Nm).
  20.  
  21. Remove transmission jack and support stand.
  22.  
  23. Connect shift rod to transfer case range lever.
  24.  
  25. Adjust transfer case shift linkage.
  26.  
  27. Lower vehicle and verify transfer case shift operation.
  28.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise the vehicle.
  6.  
  7. Remove skid plate.
  8.  
  9. Drain transfer case lubricant.
  10.  
  11. Mark front and rear propeller shaft yokes for alignment reference.
  12.  
  13. Disconnect front/rear propeller shafts at transfer case.
  14.  
  15. Disconnect transfer case position sensor connector.
  16.  
  17. Disconnect transfer case shift cable at the range lever.
  18.  
  19. Disconnect the transfer case shift cable from the shift cable bracket.
  20.  
  21. Disconnect transfer case vent hose.
  22.  
  23. Support transfer case with transmission jack.
  24.  
  25. Secure transfer case to jack with chains.
  26.  
  27. Remove the nuts attaching transfer case to transmission.
  28.  
  29. Pull transfer case and jack rearward to disengage transfer case.
  30.  
  31. Remove transfer case from under vehicle.

    Click image to see an enlarged view

    Fig. Typical transfer case mounting-Liberty

  32.  

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 on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm) torque.
  10.  
  11. Connect vent hose.
  12.  
  13. Connect transfer case position sensor connector to sensor.
  14.  
  15. Align and connect propeller shafts. Torque the rear companion flange nuts to 85 ft. lbs. (115 Nm), the front companion flange nuts to 22 ft. lbs. (30 Nm).
  16.  
  17. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  18.  
  19. Install skid plate.
  20.  
  21. Remove transmission jack and support stand.
  22.  
  23. Connect shift cable to transfer case range lever.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

NV241



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove skid plate, if equipped.
  6.  
  7. Position drain oil container under transfer case.
  8.  
  9. Remove transfer case drain plug and drain lubricant into container.
  10.  
  11. Disconnect vent hose and vacuum harness at transfer case switch.
  12.  
  13. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy access. Use channel lock style pliers to press rod out of lever grommet.
  14.  
  15. Support transmission with jackstand.
  16.  
  17. Remove rear crossmember.
  18.  
  19. Mark front and rear propeller shafts for assembly reference.
  20.  
  21. Remove front and rear propeller shafts.
  22.  
  23. Support transfer case with suitable jack. Secure transfer case to jack with safety chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Move transfer case assembly rearward until free of transmission output shaft.
  28.  
  29. Lower jack and move transfer case from under vehicle.
  30.  

To install:

  1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with transmission output shaft. Align splines by rotating transfer case rear output shaft yoke if necessary. Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission.
  2.  
  3. Install and tighten transfer case attaching nuts. Tighten nuts to 20-30 ft. lbs. (30-41 Nm).
  4.  
  5. Install rear crossmember.
  6.  
  7. Remove jackstand from under transmission.
  8.  
  9. Align and connect propeller shafts. Torque as follows:

    Front driveshaft to axle: 14 ft. lbs. (19 Nm)
     
    Front driveshaft to transfer case: 20 ft. lbs. (27 Nm)
     
    Rear driveshaft to axle: 14 ft. lbs. (19 Nm)
     
    Rear driveshaft to transfer case (Rubicon): 85 ft. lbs. (115 Nm)
     

  10.  
  11. Connect vacuum harness and vent hose.
  12.  
  13. Connect shift rod to transfer case lever or floor shift arm. Use channel lock style pliers to press rod back into lever grommet.
  14.  
  15. Adjust shift linkage, if necessary.
  16.  
  17. Fill transfer case with recommended transmission fluid and install fill plug.
  18.  
  19. Install skid plate, if equipped.
  20.  
  21. Lower vehicle
  22.  

NV241 Gen II



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Shift transfer case into NEUTRAL.
  4.  
  5. Raise vehicle.
  6.  
  7. Remove skid plate.
  8.  
  9. Drain transfer case lubricant.
  10.  
  11. Mark front and rear propeller shaft yokes for alignment reference.
  12.  
  13. Remove the front/rear propeller shafts at transfer case.
  14.  
  15. Disconnect transfer case position sensor connector from the position sensor.
  16.  
  17. Disconnect transfer case shift cable at the range lever.
  18.  
  19. Disconnect the transfer case shift cable from the shift cable bracket.
  20.  
  21. Disconnect transfer case vent hose.
  22.  
  23. Support transfer case with transmission jack.
  24.  
  25. Secure transfer case to jack with chains.
  26.  
  27. Remove nuts attaching transfer case to transmission.
  28.  
  29. Pull transfer case and jack rearward to disengage transfer case.
  30.  
  31. Remove transfer case from under vehicle.
  32.  

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 on transmission.
  8.  
  9. Install and tighten transfer case attaching nuts to 26 ft. lbs. (35 Nm) torque.
  10.  
  11. Connect vent hose.
  12.  
  13. Connect transfer case position sensor connector to sensor.
  14.  
  15. Align and connect propeller shafts. Torque the rear companion flange nuts to 85 ft. lbs. (115 Nm), the front companion flange nuts to 22 ft. lbs. (30 Nm).
  16.  
  17. Connect shift cable to transfer case range lever.
  18.  
  19. Fill transfer case with correct fluid. Check transmission fluid level. Correct as necessary.
  20.  
  21. Install skid plate.
  22.  
  23. Remove transmission jack and support stand.
  24.  
  25. Lower vehicle and verify transfer case shift operation.
  26.  

NV242



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Raise and support vehicle.
  4.  
  5. Remove skid plate, if equipped.
  6.  
  7. Position drain oil container under transfer case.
  8.  
  9. Remove transfer case drain plug and drain lubricant into container.
  10.  
  11. Disconnect vent hose and vacuum harness at transfer case switch.
  12.  
  13. Disconnect shift rod from grommet in transfer case shift lever, or from floor shift arm whichever provides easy access. Use pliers to press rod out of lever grommet.
  14.  
  15. Support transmission with jack stand.
  16.  
  17. Remove rear crossmember.
  18.  
  19. Mark front and rear propeller shafts for assembly reference.
  20.  
  21. Remove front and rear propeller shafts.
  22.  
  23. Support transfer case with suitable jack. Secure transfer case to jack with safety chains.
  24.  
  25. Remove nuts attaching transfer case to transmission.
  26.  
  27. Move transfer case assembly rearward until free of transmission output shaft.
  28.  
  29. Lower jack and move transfer case from under vehicle.
  30.  

To install:

  1. Align and seat transfer case on transmission. Be sure transfer case input gear splines are aligned with transmission output shaft. Align splines by rotating transfer case rear output shaft yoke if necessary.
    NOTE
    Do not install any transfer case attaching nuts until the transfer case is completely seated against the transmission.

  2.  
  3. Install and tighten transfer case attaching nuts. Tighten nuts to 20-30 ft. lbs. (30-41 Nm).
  4.  
  5. Install rear crossmember.
  6.  
  7. Remove jack stand from under transmission.
  8.  
  9. Align and connect propeller shafts.
  10.  
  11. Connect vacuum harness and vent hose.
  12.  
  13. Connect shift rod to transfer case lever or floor shift arm. Use pliers to press rod back into lever grommet.
  14.  
  15. Adjust shift linkage, if necessary.
  16.  
  17. Fill transfer case with recommended transmission fluid and install fill plug.
  18.  
  19. Install skid plate, if equipped.
  20.  
  21. Lower vehicle
  22.  

 
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