Installation Procedure
Apply grease the length of the splines even with the top of the splines. Adhesives, Fluids, Lubricants, and Sealers
- Transfer Case Adapter Gasket (3) - Install NEW
- Transfer Case (2) - Install
- Transfer Case Nut (1) - Install and tighten [6x] - Fastener Specifications
- Connect the wiring harness retainers.
- Remove the transmission jack from the transfer case.
Transfer Case Vent Hose (1) - Install
Reposition the wiring harness and install the wiring harness retainer (3) in to the transfer case.
- 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).
Transmission Heat Shield (3) - Install
- 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.
- Transmission Heat Shield Bolt (2) - Install and tighten - Fastener Specifications
- Transmission Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Front Bracket (2) - Install
- Catalytic Converter Brace Bracket Bolt (1) - Install and tighten [2x] - Fastener Specifications
- Connect the wiring harness retainers.
Transmission Mount (2) - Install
- 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.
- Transmission Mount Bolt (1) - Install and tighten [2x] - Fastener Specifications
Transmission Support Crossmember (1) - Install
Transmission Support Crossmember Bolt (2) - Install [4x]
- Transmission Support Crossmember Nut (1) - Install and tighten [4x] - Fastener Specifications
Transmission Mount Nut (1) - Install and tighten [2x] - Fastener Specifications
- Remove the support from the transmission.
Automatic Level Control Air Supply Reservoir (2) - Install
- Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications
Install the chassis wire harness clip (1) to the automatic level control air supply reservoir.
Install the air line (2) and clip the 2 air line retainers (1).
Install the wiring harness as necessary and connect the 4 wiring harness retainers (3).
Fuel Heater Inlet and Outlet Bolt (1) @ Transmission Support Crossmember - Install and tighten - Fastener Specifications
- Remove the transmission jack.
Propeller Shaft (1) - Install
Align the reference marks made between the rear wheel drive shaft flange and the front and rear propeller shaft.
- 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.
- Rear Propeller Shaft Bolt (1) - Install and tighten [4x] - Fastener Specifications
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).
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
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.
- 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]
- Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications
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).
Exhaust System Front Gasket (2) - Install NEW
- Nitrogen Oxides Catalytic Converter (1) - Install
Exhaust Front Pipe Nut (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Brace Bracket (3) - Install
- Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) - Install
- Catalytic Converter Brace Bracket Nut (1) - Install and tighten [2x] - Fastener Specifications
Exhaust Front Pipe Nut (1) @ Catalytic Converter Brace Bracket - Install and tighten [2x] - Fastener Specifications
Exhaust Pipe Clamp (1) - Tighten - Fastener Specifications
Coat the threads of the exhaust particulate matter sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the exhaust particulate matter sensor (1). Fastener Specifications
Coat the threads of the position 3 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the position 3 nitrogen oxides sensor (1). Fastener Specifications
Coat the threads of the position 2 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers
- Using a suitable tool, install and tighten the position 2 nitrogen oxides sensor (1). Fastener Specifications
Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. Transfer Case Fluid Replacement
- Front Wheelhouse Liner - Right Side - Install - Front Wheelhouse Liner Replacement
- Connect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
- After replacing the transfer case, perform the transfer case range actuator learn. Transfer Case Range Actuator Learn
- Inspect for Leaks
- Take the air system out of service mode.
Refer to Fastener Caution .
Refer to Component Fastener Tightening Caution .