Installation Procedure

WARNING: This page is about a different variant/trim than selected.

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Transfer Case Front Output Shaft Seal (1) - Install NEW
Using a suitable tool, tap the NEW transfer case front output shaft seal (1) in to the transfer case until it is fully seated.
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Using J-36614 Inner Pinion Bearing Installer (1), drive the transfer case front output shaft oil slinger (2) in to the transfer case until it is fully seated.
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Transfer Case Front Output Shaft Boot (1) - Install
Using the DT-35910 Drive Axle Seal Clamp Pliers (3), install and crimp the NEW transfer case front output shaft boot clamp (2) until the gap at the base of the ear (a) is 1.5 mm (0.059 in).
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Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers
Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.
Align the reference marks made between the transfer case front output shaft and the front axle propeller shaft.
Front Axle Propeller Shaft (3) - Install
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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:
1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth.
2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive.
3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers
4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
Front Axle Propeller Shaft Washer (3) - Install [3x]

CAUTION:

Refer to Fastener Caution .

Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
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Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.
Using the DT-35910 Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).
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{If equipped} Transfer Case Skid Shield (2) - Install - Transfer Case Skid Shield Replacement
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CAUTION:
Refer to Component Fastener Tightening Caution .

NOTE:
A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

Install and tighten the bank 1, sensor 2 heated oxygen sensor (1) using a suitable tool. Fastener Specifications
Connect the heated oxygen sensor electrical connector.
Remove the support and lower the vehicle.