Companion Flange And Range Lever

WARNING: This page is about a different car, the 2005 Jeep Liberty. However, it is still accessible from the selected car via links, so may be relevant.

Install range lever and bolt on sector shaft. See Fig 1. Tighten bolt to 27-34 N.m (20-25 ft. lbs.) torque.
Inspect the o-ring on the transfer case position sensor. Replace the O-ring if necessary.

Install the transfer case position sensor in the front case. See Fig 2. Tighten sensor to 20-34 N.m (15-25 ft. lbs.) torque.

Fig 1: Remove/Install Lever Bolt - Typical

Courtesy of DAIMLERCHRYSLER CORP.

1 - RANGE LEVER

2 - RANGE LEVER BOLT

3 - TRANSFER CASE

Fig 2: Remove/Install Transfer Case Position Sensor

Courtesy of DAIMLERCHRYSLER CORP.

1 - TRANSFER CASE POSITION SENSOR

2 - TRANSFER CASE

Install new seal washer on front output shaft. See Fig 3.
Lubricate companion flange hub with transmission fluid and install flange onto the front output shaft.
Install new seal washer on front shaft.
Install new flange nut onto front output shaft.
Tighten flange nut to 122-176 N.m (90-130 ft. lbs.) torque.

Fig 3: Companion Flange Seal Washer Installation

Courtesy of DAIMLERCHRYSLER CORP.

1 - SEAL WASHER