Installation Procedure
- Clean the contact surfaces between the transfer case and the transfer case bracket.
- Install a new transfer case-to-transfer case bracket seal (1).
- Support the transfer case with a suitable jack, and secure with suitable straps.
- Raise and align the transfer case in the correct position in relation to the transmission.
- Install the transfer case (2) to the transfer case bracket.
- Install the NEW transfer case-to-transfer case bracket fasteners (1) and tighten to 100 (74 lb ft) plus 30-45 degrees.
- Install the intermediate drive shaft into the transfer case. Refer to Front Wheel Drive Intermediate Shaft Replacement .
- Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side .
- Install the propeller shaft. Refer to Two-Piece Propeller Shaft Replacement .
- Connect the transfer case vent hose (1) to the transfer case.
- Install the front exhaust pipe. Refer to Exhaust Front Pipe Replacement (2H0, LUV) .
- Fill the transmission with fluid. Refer to Transmission Fluid Drain and Fill .
- Check the transfer case fluid. Refer to Approximate Fluid Capacities .
CAUTION:
Refer to Fastener Caution .
NOTE:
The intermediate drive shaft is to be installed into the transfer case assembly after the transfer case assembly is installed into the vehicle. Prior to installation of the shaft into the assembly, seal protector DT-50937 must be installed to protect the front wheel drive intermediate shaft seal.