Removal And Installation

REMOVAL 

1. Disengage the Manual Park Release (MPR) lever. Refer to DISENGAGE MANUAL PARK RELEASE (MPR) .
2. Raise vehicle and support the vehicle. Refer to HOISTING, STANDARD PROCEDURE .
   NOTE:

   The air suspension system will auto-disable when lifted on a frame hoist, or when jacking one corner of the vehicle. The air suspension may attempt to change height slightly prior to switching to auto-disable. A manual disable is also available by pressing the "Up" and "Down" switches of the terrain select switch simultaneously for more that 5 seconds. The air suspension system will return to normal operation when the vehicle speed reaches 25 km/h (15 mph).

   NOTE:

   IMPORTANT: DO NOT FILL TRANSFER CASE USING FILL PLUG (LABELED (1) IN ILLUSTRATION) LOCATED AT THE REAR OF THE HOUSING. THE TRACKHAWK HAS A NEW FILL PLUG LOCATED ON THE RIGHT SIDE OF THE TRANSFER CASE. 

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3. Remove the transfer case drain plug (2) and drain the transfer case fluid.

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4. Remove the transfer case fill plug (1) from the NEW  location on the right side of the transfer case. This is the CORRECT  transfer case fill plug location.
5. Support the transmission with a suitable jack stand.
6. Remove the skid plate, if equipped. Refer to PLATE, SKID, TRANSFER CASE, REMOVAL .
7. Remove the frame cross-member. Refer to CROSSMEMBER, REAR, REMOVAL .
   CAUTION:

   Do not allow propeller shafts to hang at attached end. Damage to joint can result.

8. Disconnect the front driveshaft from the transfer case.
   NOTE:

   It may be necessary to remove the heat shield to access the transfer case wire harness connectors.

9. Remove the rear driveshaft. Refer to SHAFT, DRIVE, REAR, REMOVAL .
10. Disconnect the transfer case shift motor and mode sensor wire harness connector.
11. Disconnect the transfer case vent hose.
12. Support the transfer case with a suitable jack.
13. Secure the transfer case to the jack with chains.

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14. Remove the transfer case bolts (3).
15. Pull the transfer case (1) and jack rearward to disengage the transfer case from the transmission (2).
16. Remove the transfer case (1) from under vehicle.

INSTALLATION 

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1. Mount the transfer case (1) on a suitable jack.
2. Secure the transfer case to the jack with chains.
3. Position the transfer case under vehicle.
4. Align the transfer case (1) and the transmission (2) shafts and install transfer case onto transmission.
5. Install and tighten the transfer case attaching bolts (3) to the proper specification. Refer to TORQUE SPECIFICATIONS  .
6. Connect the transfer case vent hose to the transfer case.
7. Install the frame crossmember Refer to CROSSMEMBER, REAR, INSTALLATION .
8. Install the skid plate, if equipped. Refer to PLATE, SKID, TRANSFER CASE, INSTALLATION .
9. Remove the jack and support stand.
10. Install the front driveshaft. Refer to SHAFT, DRIVE, FRONT, INSTALLATION .
11. Install the rear driveshaft. Refer to SHAFT, DRIVE, REAR, INSTALLATION .

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12. Fill the transfer case at the NEW  fill plug (1) with the correct fluid. Refer to TRANSFER CASE FLUID DRAIN/REFILL  .
13. Connect the shift motor and encoder wire harness connectors.
14. Remove the support and lower the vehicle.
15. Engage the MPR lever.
16. If replacing the transfer case, Drivetrain Control Module (DTCM), or both, use the scan tool to perform the Non-Volatile Memory Reset procedure.
17. Perform the DTCM verification test. Refer to DTCM VERIFICATION TEST .