Removal Procedure
- Start vehicle and shift the transfer case to 2WD/2High.
- Turn the vehicle off.
- Remove the negative battery cable from the battery. Battery Negative Cable Disconnection and Connection (without K4B)Battery Negative Cable Disconnection and Connection (with K4B)
Drain the fluid from the transfer case. Transfer Case Fluid Replacement
Disconnect the transfer case two/four wheel drive actuator electrical connector (1).
- Disconnect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Disconnect the wiring harness retainers from the transfer case and position the wiring harness out of the way.
Front Axle Propeller Shaft Slip Yoke Boot Clamp (1) @Front Axle Propeller Shaft - Remove and DISCARD
Mark a reference point between the front axle propeller shaft and the front axle drive pinion flange.
- Front Axle Propeller Shaft Bolt (2) - Remove [4x]
- Front Axle Propeller Shaft Retainer (1) - Remove [2x]
- CAUTION:
When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, this may lead to premature failure of the joint.
Front Axle Propeller Shaft (1) - Remove
Front Axle Propeller Shaft Slip Yoke Boot Clamp (2) - Remove and DISCARD
- Front Axle Propeller Shaft Slip Yoke Boot (1) - Remove
Disconnect the vent hose (1) from the transfer case.
Mark the relationship of the propeller shaft (2) to the rear wheel drive shaft flange.
- Rear Propeller Shaft Bolt (1) - Remove [8x]
Propeller Shaft (1) - Remove
- NOTE:
Left side shown, right side similar.
Front Wheelhouse Liner-Right Side (3) - Remove - Front Wheelhouse Liner Replacement
Emission Reduction Fluid Injector Clamp (1) - Remove
- Reductant Fluid Injector (2) - Remove
- Exhaust System Front Gasket (3) - Remove and DISCARD
- Clean the exhaust mounting flange and injector mounting surfaces to remove any soot or emission reduction fluid deposits.
Disconnect the exhaust temperature sensor position 3 electrical connector (2).
- Exhaust Temperature Sensor Clip (3) @Exhaust Temperature Sensor (1) - Unclip [2x]
Exhaust Temperature Sensor- Position 3 (1) - Remove
Disconnect the nitrogen oxides sensor position 2 electrical connector (3).
- Nitrogen Oxides Sensor Bolt (2) - Remove [2x]
- Nitrogen Oxides Sensor- Position 2 (4) - Remove
Nitrogen Oxides Sensor Cable Clip (1) @Nitrogen Oxides Sensor- Position 2 (2) - Remove [2x]
Nitrogen Oxides Sensor- Position 2 (1) - Remove
- Support the transmission with a suitable jack.
Fuel Heater Inlet and Outlet Bolt (2) @Transmission Support Crossmember - Remove
- Hose Clip (3) @Transmission Support Crossmember - Remove
- Fuel Cooler Coolant Cooler Inlet Hose (4) - Reposition away
Transmission Mount Nut (1) - Remove [3x]
Fuel Heater Inlet and Outlet Nut (1) - Remove [2x]
- Remove the auxiliary radiator outlet hose (2) from the exhaust bracket stud and the transmission fluid cooler pipe stud and reposition the auxiliary radiator outlet hose.
Fuel Heater Inlet and Outlet Nut (2) - Remove
- Exhaust Front Bracket (4) - Reposition
- NOTE:
Clip is released to allow for more room for pipe movement when removing the nitrogen oxides catalytic converter.
Transmission Fluid Cooler Inlet and Outlet Pipe Clip (1) - Release
Exhaust Bracket Stud (1) - Remove
- Catalytic Converter Brace Bracket Bolt (2) - Remove
Remove the exhaust front bracket and exhaust front insulator (1) as an assembly.
Exhaust Front Pipe Nut (1) - Remove [4x]
Exhaust System Rear Nut (1) - Remove [4x]
Transmission Support Crossmember Nut (2) - Remove [4x]
- Reposition the nitrogen oxides catalytic converter for access to remove the right side inner transmission support crossmember bolt (1).
- Transmission Support Crossmember Bolt (1) - Remove [4x]
Transmission Support Crossmember (1) - Remove
Transmission Mount Bolt (2) - Remove and DISCARD [2x]
- Transmission Mount (1) - Remove and DISCARD
With the aid of an assistant, reposition the transmission and lower the nitrogen oxides catalytic converter (1) from the vehicle.
- Exhaust System Seal (2) - Remove and DISCARD
- Exhaust System Seal (3) - Remove and DISCARD
- Using a suitable transmission jack, support the transfer case.
- Using suitable straps or chains, secure the transfer case to the transmission jack.
- NOTE:
This measurement step MUST be performed before removing or loosening any components or the measurement will be inaccurate.
Measure and record the distance (a) between the torsion bar adjust nut (1) and the head of the torsion bar adjust bolt (2) for both the left and right side torsion bars.
- CAUTION:
Use care when handling the torsion bars in order to avoid chipping or scratching the coating. Damage to the coating will result in premature failure of the torsion bars.
NOTE:- The left and right torsion bars are NOT interchangeable.
- Ensure a NEW torsion bar is installed in the same direction as the OLD torsion bar.
- The torsion bars are only designed to be torqued in one direction.
- The correct direction for each torsion bar is marked on the bar.
Using the CH-48809 Torsion Bar Unloading/Loading (1) apply tension to the left and right side torsion bar adjust arms until the load is removed from the torsion bar adjust nut (2).
- Remove the left and right side torsion bar adjust bolts (3) from the torsion bar adjust nut (2).
- Slide the left and right side torsion bar adjust nuts (2) out of the torsion bar support.
- Release tension on the left and right side front torsion bars and remove the CH-48809 Torsion Bar Unloading/Loading (1) from the torsion bar support.
Slide the left and right side front torsion bars (2) forward and remove the torsion bar adjust arms (1).
Torsion Bar Support Bolt (1) - Remove [2x]
- Torsion Bar Support (2) - Remove
Disconnect the wiring harness retainers and reposition the harness as necessary.
- Transfer Case Bolt (1) - Remove [12x]
- Transfer Case Assembly (2) - Remove
Automatic Transmission Case Extension Seal (1) - Remove
- Inspect the automatic transmission case extension seal, if damaged replace with new.
Do not use a prying tool to remove the injector.
After removing the injector, wipe any residual DEF with a clean towel to avoid urea crystal build up at the connection during installation. Urea crystal build-up can result in a future leak.