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Transfer Case Shift Lever - New Assembly: Installation

CAUTION: A break-away pin, found only on a new transfer case control lever assembly detent plate, holds the lower shifter arm in the 2H detent position during installation. This ensures correct transfer case gear engagement during transfer case operation. Carry out this procedure only if installing a new transfer case control lever assembly. If reinstalling the original transfer case control lever assembly, see TRANSFER CASE SHIFT LEVER - ORIGINAL ASSEMBLY .
  1. Verify that the break-away pin on the detent plate is inserted into the hole in the lower shifter arm.
    Fig 1: Verifying Break-away Pin Installation
    G02189095
    2. CAUTION: Do not tighten the bolt that attaches the transfer case control lever assembly to the transmission case at this time.
    Fig 2: Inserting NEW Transfer Case Control Lever Assembly Pivot Bolt
    G02189096
  2. Align the new transfer case control lever assembly pivot bolt over the correct mounting hole in the transmission case and start the bolt into the threaded hole by hand.
    1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, install the new bolt in the forward (LH) threaded hole in the transmission case.
    2. For vehicles with a gasoline engine and automatic transmission, install the new bolt in the rearward (RH) threaded hole in the transmission case.
  3. Position the detent plate locating pin in the unused threaded hole in the transmission case.
    1. For vehicles with a gasoline engine and manual transmission, or a diesel engine and manual or automatic transmission, position the pin in the rearward (RH) threaded hole in the transmission case.
    2. For vehicles with a gasoline engine and automatic transmission, position the pin in the forward (LH) threaded hole in the transmission case.
    Fig 3: Positioning Detent Plate Locating Pin
    G02189097
    4. CAUTION: Verify that the control rod is still attached correctly to the transfer case.
    CAUTION: Verify that the transfer case is still in 2H.
    Fig 4: Connecting Control Rod To Lower Shifter Arm
    G02189098
  4. Connect the control rod to the lower shifter arm.
  5. Hold the transfer case control lever assembly and tighten the bolt.
    Fig 5: Tightening Transfer Case Control Lever Assembly Bolt
    G02189099
  6. Lower the vehicle.
  7. Position the shift lever with the bezel and boot assembly and install the bolt.
    Fig 6: Positioning Shift Lever With Bezel & Boot Assembly
    G02189100
  8. Position the bezel and boot assembly and install the screws.
    9. Fig 7: Installing Bezel & Boot Assembly Screws
    G02189101
  9. Shift the transfer case shift lever to break the locating pin. Verify the shift sequence from 2H to 4L to 2H.
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