Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
2. Remove the engine belly pan. Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
3. Remove the exhaust pipe. Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
4. Remove the transmission crossmember. Refer to CROSSMEMBER, TRANSMISSION, REMOVAL AND INSTALLATION .
5. Remove the front and rear drive shafts. Refer to REMOVAL AND INSTALLATION .

   Courtesy of CHRYSLER GROUP, LLC

6. Disconnect the Drivetrain Control Module (DTCM) wire harness connector (1).

   Courtesy of CHRYSLER GROUP, LLC

7. Remove the transfer case bolts (1a) and remove the transfer case (1b).

   Courtesy of CHRYSLER GROUP, LLC

8. Remove and discard the transfer case to transmission seal (1).

INSTALLATION 

Courtesy of CHRYSLER GROUP, LLC

1. Install a NEW  transfer case to transmission seal using (special tool #2046100090, Installer, Transfer Case Differential Oil Seal) and (special tool #C-4171, Driver Handle, Universal).
   Fig 1: Transfer Case Bolts Tightening Sequence

   Courtesy of CHRYSLER GROUP, LLC
2. Install the transfer case (1a), the transfer case bolts (1b) and in the order shown, tighten to the proper Refer to TECHNICAL SPECIFICATIONS .

   Courtesy of CHRYSLER GROUP, LLC

3. Connect the DTCM wire harness connector (1).
4. Install the exhaust pipe Refer to PIPE, EXHAUST, REMOVAL AND INSTALLATION .
5. Install the transmission crossmember Refer to CROSSMEMBER, TRANSMISSION, REMOVAL AND INSTALLATION .
6. Install the front and rear drive shafts Refer to REMOVAL AND INSTALLATION .
7. Verify that the transfer case is filled to the proper fluid level using the specified fluid. Refer to FLUID, STANDARD PROCEDURE . Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
8. Verify that the transmission is filled to the proper fluid level using the specified fluid. Refer to appropriate service information . Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
9. Install the engine belly pan Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
10. Remove the support and lower the vehicle.
11. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
12. When installing a new transfer case, connect the diagnostic scan tool, enter "miscellaneous functions" of the Drive Train Control Module (DTCM) and run the self-learning procedure for the transfer case.
13. Road test the vehicle to verify the repair.