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Transfer Case Assembly: Installation

  1. Fit NEW input shaft oil seal. See OIL SEAL - INPUT SHAFT  .
  2. Clean transfer box to transfer box mating faces.
  3. Raise transfer box on jack and align to guide studs LRT-41-009.
  4. Clean transfer box to transfer box bolt threads.
  5. Apply sealant, Part No. STC 50552 to bolt and stud threads.
  6. Fit and lightly tighten 2 bolts and nut securing transfer box to transmission. If NEW stud is to be fitted, apply sealant, Part No. STC 50552 to stud threads and tighten to 45 N.m (33 ft. lbs.).
  7. Remove guide studs, fit and lightly tighten 3 bolts.
  8. Tighten bolts and nut by diagonal selection to 45 N.m (33 ft. lbs.).
  9. Position transfer box right hand mounting and tighten bolts to 85 N.m (63 ft. lbs.).
  10. Tighten transfer box right hand mounting nut to 48 N.m (35 ft. lbs.).
  11. Fit nut to left hand mounting and tighten to 48 N.m (35 ft. lbs.).
  12. Remove 4 bolts securing support plate to transmission jack.
  13. Remove 4 bolts securing support plate LRT-99-010 to transfer box and remove plate.
  14. Clean threads of bottom plate bolts.
  15. Apply sealant, Part No. STC 50552 to threads of 4 bottom plate bolts.
  16. Fit 4 bolts securing bottom plate and tighten to 25 N.m (18 ft. lbs.).
  17. Using NEW washers position breather pipe and tighten banjo bolt.
  18. Connect multiplug to transfer box neutral switch and secure harness.
  19. On vehicles up to 2003 Model Year, if fitted, connect Lucars to differential lock switch and multiplugs to high/low ratio switch and neutral sensor.
  20. On vehicles 2003 Model Year onwards, if fitted, connect differential lock warning lamp multiplugs, secure harness.
  21. Connect multiplug to reverse lamp switch.
  22. If fitted, connect Lucars to oil temperature switch.
  23. Position high/low ratio selector cable and secure with C clip and clevis pin.
  24. If fitted, position differential lock selector cable to differential lock selector cable abutment bracket and tighten locknuts sufficiently to retain cable.
  25. If fitted, fit differential lock selector cable to transfer box and secure with clevis pin.
  26. If fitted, adjust differential lock selector cable. See CABLE - DIFFERENTIAL LOCK SELECTOR  under ADJUSTMENTS.
  27. Models fitted with high/low shift interlock solenoid, position interlock solenoid harness to high/low shift cable, fit sleeve around cable and harness; secure sleeve.
  28. Models fitted with high/low shift interlock solenoid, connect solenoid multiplug to main harness and secure multiplug to bracket.
  29. Secure cable to fuel pipes with NEW cable ties.
  30. Clean handbrake back plate and mating face.
  31. Position handbrake back plate, fit bolts and tighten to 75 N.m (55 ft. lbs.).
  32. Clean handbrake drum.
  33. Fit handbrake drum and tighten retaining screw.
  34. Fit front propeller shaft. See DRIVE SHAFT - FRONT in DRIVESHAFT & UNIVERSAL JOINTS article.
  35. Fit rear propeller shaft. See DRIVE SHAFT - REAR in DRIVESHAFT & UNIVERSAL JOINTS article.
  36. Clean exhaust silencer and tail pipe mating faces.
  37. Position silencer and secure on mountings, using a NEW gasket align to tail pipe, fit nuts and tighten to 25 N.m (18 ft. lbs.).
  38. Position rear crossmember, fit bolts and tighten to 26 N.m (19 ft. lbs.).
  39. Refill transfer box with oil. See TRANSFER BOX DRAIN & REFILL  .
  40. Fit front exhaust pipe. See FRONT EXHAUST PIPE  .
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