Removal And Installation

REMOVAL 

1. Disconnect and isolate the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector first before disconnecting the negative battery cable.
2. Remove the engine belly pan. Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
3. Remove the exhaust resonator. Refer to RESONATOR, EXHAUST, REMOVAL AND INSTALLATION .
4. Remove the transmission crossmember. Refer to CROSSMEMBER, TRANSMISSION, REMOVAL AND INSTALLATION .
5. Remove the front and rear drive shafts. Refer to REMOVAL AND INSTALLATION .

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6. Disconnect the Drivetrain Control Module (DTCM) wire harness connector (1).

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7. Remove the transfer case bolts (1a) and remove the transfer case (1b).

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8. Remove and discard the transfer case to transmission seal (1).

INSTALLATION 

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1. Install a NEW  transfer case to transmission seal (1).
   Fig 1: Transfer Case Mounting Tightening Sequence

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2. Install the transfer case (1a), the transfer case bolts (1b) and in the order shown in illustration, tighten to the proper specification. Refer to TECHNICAL SPECIFICATIONS .

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3. Connect the DTCM wire harness connector (1).
4. Install the exhaust resonator. Refer to RESONATOR, EXHAUST, REMOVAL AND INSTALLATION .
5. Install the transmission crossmember. Refer to CROSSMEMBER, TRANSMISSION, REMOVAL AND INSTALLATION .
6. Install the front and rear drive shafts. Refer to REMOVAL AND INSTALLATION .
7. Verify that the transfer case and transmission are filled to the proper fluid level using the specified fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS, SPECIFICATIONS .
8. Install the engine belly pan. Refer to BELLY PAN, ENGINE, REMOVAL AND INSTALLATION .
9. Remove the support and lower the vehicle.
10. Connect the negative battery cable. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector to the negative battery cable.
11. When installing a new transfer case, connect the diagnostic scan tool, enter "miscellaneous functions" of the Drive Train Control Module (DTCM) and run the self-learning procedure for the transfer case.
12. Road test the vehicle to verify the repair.