Installation Procedure
Install a new transfer case input shaft seal (3) using the DT-53018 Transfer Case Front Input Shaft Seal Installer (2), and J-8092 Driver Handle (1).
Automatic Transmission Case Extension Seal (1) - Install
- NOTE:
It is critical to clean the threads on the bolt and in the transmission with brake cleaner, then blow out the hole with compressed air to ensure there is no fluid left in it.
Clean and inspect the transmission mating surface and bolt holes.
- Transfer Case (2) - Install
- Transfer Case Bolt (1) - Install and tighten in sequence [12x] - Fastener Specifications
- Install the wiring harness.
Torsion Bar Support (2) - Install
- Torsion Bar Support Bolt (1) - Install and tighten [2x] - Fastener Specifications
Install the left and right side front torsion bar adjust arms (1) into the torsion bar support and slide the front torsion bar (2) into the front torsion bar adjust arms (1).
Install the CH-48809 Torsion Bar Unloading/Loading (1) and apply sufficient tension to the left and right side front torsion bars to allow installation of the torsion bar adjust nuts (2).
- Slide the left and right side torsion bar adjust nuts (2) into the torsion bar support.
- Apply a thin coating of grease to the left and right side torsion bar adjust bolts (3). Adhesives, Fluids, Lubricants, and Sealers
- Loosely install the left and right side torsion bar adjust bolts (3).
- Release tension from the left and right side front torsion bars and remove the CH-48809 Torsion Bar Unloading/Loading (1).
Tighten the left and right side torsion bar adjust bolts (2) into the torsion bar adjust nuts (1) until the previously recorded measurement (a) is achieved.
- Remove the transmission jack from the transfer case.
Exhaust System Seal (3) - Install NEW
- Exhaust System Seal (2) - Install NEW
- With the aid of an assistant, reposition the transmission and install the nitrogen oxides catalytic converter (1) to the vehicle.
Transmission Mount (1) - Install NEW
- Transmission Mount Bolt (2) - Install NEW and tighten [2x] - Fastener Specifications
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (1) - Install [4x]
- Transmission Support Crossmember Nut (2) - Install and tighten [4x] - Fastener Specifications
- Reposition the nitrogen oxides catalytic converter.
Transmission Mount Nut (1) - Install and tighten [3x] - Fastener Specifications
- Remove the transmission jack.
Exhaust System Rear Nut (1) - Install and tighten [4x] - Fastener Specifications
Exhaust Front Pipe Nut (1) - Install and tighten [4x] - Fastener Specifications
Hose Clip (3) @Transmission Support Crossmember - Install
- Fuel Heater Inlet and Outlet Bolt (2) @Transmission Support Crossmember - Install and tighten - Fastener Specifications
Install the exhaust front bracket and exhaust front insulator (1) as an assembly.
Catalytic Converter Brace Bracket Bolt (2) - Install and hand tighten
- Exhaust Bracket Stud (1) - Install and tighten - Fastener Specifications
- Catalytic Converter Brace Bracket Bolt (2) - Tighten - Fastener Specifications
Transmission Fluid Cooler Inlet and Outlet Pipe Clip (1) - Install
Exhaust Front Bracket (4) - Install
- Fuel Heater Inlet and Outlet Nut (2) - Install and tighten - Fastener Specifications
Install the auxiliary radiator outlet hose (2) to the exhaust bracket stud and the transmission fluid cooler pipe stud.
- Fuel Heater Inlet and Outlet Nut (1) - Install and tighten [2x] - Fastener Specifications
Coat the threads of the nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Nitrogen Oxides Sensor- Position 2 (1) - Install and tighten - Fastener Specifications
Nitrogen Oxides Sensor Cable Clip (1) @Nitrogen Oxides Sensor- Position 2 (2) - Install [2x]
Nitrogen Oxides Sensor- Position 2 (4) - Install
- Nitrogen Oxides Sensor Control Module Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Connect the nitrogen oxides sensor electrical connector (3).
Exhaust Temperature Sensor- Position 3 (1) - Install and tighten - Fastener Specifications
Exhaust Temperature Sensor Clip (3) @Exhaust Temperature Sensor- Position 3 (1) - Engage [2x]
- Connect the exhaust temperature sensor - position 3 electrical connector (2).
Exhaust System Front Gasket (3) - Install NEW
Align the 3 tabs (1) and insert into 3 slots on exhaust mounting flange.
- NOTE:
Prior to installing the injector, make sure the parts are perfectly clean. If required, clean out with distilled water in order to dissolve any residual crystal.
Reductant Fluid Injector (2) - Install
- Emission Reduction Fluid Injector Clamp (1) - Install and tighten - Fastener Specifications
- Front Wheelhouse Liner-Right Side - Install - Front Wheelhouse Liner Replacement
Propeller Shaft (1) - Install
Align the reference marks made between the rear wheel drive shaft flange and the propeller shaft (2).
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Install the 8 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications
Connect the vent hose (1) to the transfer case.
Apply a thin layer of grease to the front axle propeller shaft (3) splines. Adhesives, Fluids, Lubricants, and Sealers
- Loosely install a NEW front axle propeller shaft slip yoke boot clamp (1) to the front axle propeller shaft slip yoke boot (2) groove.
- Front Axle Propeller Shaft (3) - Install
Align the reference marks made between the front axle propeller shaft and the front axle drive pinion flange.
- If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps:
- Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
- Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
- Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
- Ensure there are no gaps in the thread locking adhesive once applied to the component.
- Front Axle Propeller Shaft Retainer (2) - Install NEW [2x]
- Front Axle Propeller Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
Ensure the front axle propeller shaft slip yoke boot (2) is fully engaged into the groove of the front axle propeller shaft.
- Using the DT-35910 Drive Axle Seal Clamp Pliers (1), crimp the front axle propeller shaft slip yoke boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Connect the transfer case two/four wheel drive actuator electrical connector (1).
- Position the wiring harness and connect the harness retainers.
- Fill the transfer case to the proper level with the recommended fluid. Transfer Case Fluid Replacement
{If equipped} Transfer Case Skid Shield (2) - Install
- {If equipped} Transfer Case Skid Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (without K4B)Battery Negative Cable Disconnection and Connection (with K4B)
- Start the engine and check for exhaust leaks.
- With the engine running, shift the transfer case through all modes and ranges to verify correct operation.
- Measure and adjust the trim height as necessary. Trim Height Inspection
Refer to Fastener Caution .
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
Refer to Component Fastener Tightening Caution .