Transfer Case Assembly Replacement (L84, L87 without F47) (1)

Transfer Case Assembly Replacement (L84, L87 without F47) Single Use Fasteners and Components Exhaust System Seal [2x] Transfer Case Front Output Shaft Boot Clamp Transfer Case Adapter Gasket Special Tools DT-35910 Drive Axle Seal Clamp Pliers Equivalent regional tools: Special Tools

Warning

In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.

Warning

Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.

Warning

Refer to Safety Glasses Warning. Removal Procedure

1. Place the transmission in neutral service mode. Neutral Service Mode
2. Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection
3. Front Wheelhouse Liner - Left Side and Right Side » Remove — Front Wheelhouse Liner Replacement

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 1

4. Evaporative Emission Canister Bracket Nut (1) » Loosen [2x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 2

5. Evaporative Emission Canister Bracket Bolt (1) » Remove
6. Evaporative Emission Hose (2) » Disconnect [3x] — Plastic Collar Quick Connect Fitting Service

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 3

7. Evaporative Emission Canister (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 4

8. Drain the fluid from the transfer case. Transfer Case Fluid Replacement

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 5

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution.

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

9. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 2 » Disconnect
10. Using a suitable tool, remove the heated oxygen sensor bank 1 sensor 2 (1).

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 6

11. Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft » Remove and DISCARD
12. Reposition the transfer case front output shaft boot (2) and mark a reference point between the front axle propeller shaft and the transfer case front output shaft.

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 7

13. Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
14. Front Axle Propeller Shaft Bolt (2) » Remove [6x]
15. Front Axle Propeller Shaft Washer (3) » Remove [3x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 8

16. Front Axle Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 9

17. Transfer Case Front Output Shaft Boot Clamp (2) @ Transfer Case » Remove and DISCARD
18. Transfer Case Front Output Shaft Boot (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 10

19. Mark the relationship of the propeller shaft to the differential drive pinion gear yoke.
20. Rear Propeller Shaft Bolt (1) » Remove [4x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 11

21. Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 12

22. Exhaust Heat Shield Bolt (1) » Remove
23. Exhaust Front Pipe Heat Shield (2) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 13

24. Exhaust Heat Shield Bolt (1) » Remove
25. Exhaust Front Pipe Heat Shield (2) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 14

Caution

Refer to Heated Oxygen and Oxygen Sensor Caution.

Note

The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor. The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).

26. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 1 » Disconnect
27. Using a suitable tool, remove the heated oxygen sensor bank 1 sensor 1 (1)

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 15

28. Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 1 » Disconnect

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 16

29. Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 2 » Disconnect

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 17

30. Exhaust Pipe Clamp (1) » Loosen
31. Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) » Separate

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 18

32. Exhaust Front Pipe Nut (1) - Left Side » Remove [3x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 19

33. Exhaust Front Pipe Nut (1) - Right Side » Remove [3x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 20

34. If equipped, remove the wiring harness (2) from the 3 wiring harness retainers (1) and reposition the wiring harness as necessary.
35. Support the transmission with a suitable jack.

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 21

36. Transmission Mount Nut (1) » Remove [2X]
37. Transmission Support Crossmember Nut (2) » Remove [4x]
38. Transmission Support Crossmember Bolt (3) » Remove [4x]

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 22

39. Transmission Support Crossmember (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 23

40. Three-Way Catalytic Converter (1) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 24

41. Exhaust System Seal - Left Side (1) » Remove and DISCARD

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 25

42. Exhaust System Seal - Right Side (1) » Remove and DISCARD

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 26

43. Disconnect the transmission wiring harness retainer (1) and reposition the harness as necessary.

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 27

44. Transmission Heat Shield Bolt (2) » Remove
45. Transmission Heat Shield Bolt (1) » Remove [2x]
46. Transmission Heat Shield (3) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 28

47. Transmission Mount Bolt (1) » Remove [2x]
48. Transmission Mount (2) » Remove

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 29

49. Disconnect the transfer case two/four wheel drive actuator electrical connector (1).
50. Disconnect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
51. Remove the wiring harness retainer (3) from the transfer case and position the wiring harness out of the way.

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 30

52. Transfer Case Vent Hose (1) » Remove
53. Using a suitable transmission jack, support the transfer case.
54. Using suitable straps or chains, secure the transfer case to the transmission jack.

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 31

55. Transfer Case Nut (1) » Remove [6x]

56. Transfer Case (2) » Remove

57. Transfer Case Adapter Gasket (3) » Remove and DISCARD Installation Procedure

58. Apply grease the length of the splines even with the top of the splines. Adhesives, Fluids, Lubricants, and Sealers

59. Transfer Case Adapter Gasket (3) » Install NEW

60. Transfer Case (2) » Install

Caution

Refer to Fastener Caution.

4. Transfer Case Nut (1) » Install and tighten [6x] — Fastener Specifications

5. Remove the transmission jack from the transfer case.

6. Transfer Case Vent Hose (1) » Install

7. Reposition the wiring harness and install the wiring harness retainer (3) in to the transfer case.

8. Connect the transfer case two/four wheel drive actuator position sensor electrical connector (2).

9. Connect the transfer case two/four wheel drive actuator electrical connector (1).

10. Transmission Mount (2) » Install

11. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 11.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 11.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 11.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 11.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

12. Transmission Mount Bolt (1) » Install and tighten [2x] — Fastener Specifications

13. Transmission Heat Shield (3) » Install

14. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 14.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 14.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 14.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 14.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

15. Transmission Heat Shield Bolt (2) » Install and tighten — Fastener Specifications

16. Transmission Heat Shield Bolt (1) » Install and tighten [2x] — Fastener Specifications

17. Reposition the transmission wiring harness and connect the wiring harness retainer (1).

18. Exhaust System Seal - Right Side (1) » Install NEW

19. Exhaust System Seal - Left Side (1) » Install NEW

20. Three-Way Catalytic Converter (1) » Install

21. Transmission Support Crossmember (1) » Install

22. Transmission Support Crossmember Bolt (3) » Install [4x]

23. Transmission Support Crossmember Nut (2) » Install and tighten [4x] — Fastener Specifications

24. Transmission Mount Nut (1) » Install and tighten [2x] — Fastener Specifications

25. Remove the transmission jack.

26. If equipped, position the wiring harness (2) as necessary then install the harness into the 3 wiring harness retainers (1).

27. Exhaust Front Pipe Nut - Right Side (1) » Install and tighten [3x] — Fastener Specifications

28. Exhaust Front Pipe Nut - Left Side (1) » Install and tighten [3x] — Fastener Specifications

29. Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) » Connect

30. Exhaust Pipe Clamp (1) » Tighten — Fastener Specifications

31. Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 2 » Connect

32. Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 1 » Connect

Caution

Refer to Component Fastener Tightening Caution.

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

33. Using a suitable tool, install and tighten the heated oxygen sensor bank 1 sensor 1 (1). Fastener Specifications

34. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 1 » Connect

35. Exhaust Front Pipe Heat Shield (2) » Install

36. Exhaust Heat Shield Bolt (1) » Install and tighten — Fastener Specifications

37. Exhaust Front Pipe Heat Shield (2) » Install

38. Exhaust Heat Shield Bolt (1) » Install and tighten — Fastener Specifications

39. Propeller Shaft (1) » Install

40. Align the reference marks made between the rear wheel drive shaft flange and the front and rear propeller shaft.

41. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 41.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 41.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 41.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 41.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

42. Rear Propeller Shaft Bolt (1) » Install and tighten [4x] — Fastener Specifications

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 32

43. Transfer Case Front Output Shaft Boot (1) » Install
44. Using the DT-35910 Drive Axle Seal Clamp Pliers (3), install and crimp the NEW transfer case front output shaft boot clamp (2) until the gap at the base of the ear (a) is 1.5 mm (0.059  in).

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 33

45. Apply a thin layer of grease to the splines of the transfer case front output shaft (1). Adhesives, Fluids, Lubricants, and Sealers

46. Loosely install a NEW transfer case front output shaft boot clamp (2) to the transfer case front output shaft boot groove.

47. Align the reference marks made between the transfer case front output shaft and the front axle propeller shaft.

48. Front Axle Propeller Shaft (3) » Install

49. If NEW threaded components are being installed, loosen the adhesive using a metal pick or similar tool before proceeding. If threaded components are reused, prepare the threaded components using the following steps: 49.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 49.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 49.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 49.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

50. Align the reference marks made between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.

51. Front Axle Propeller Shaft Washer (3) » Install [3x]

52. Install the 6 front axle propeller shaft bolts (2) and tighten in a crisscross pattern. Fastener Specifications

Transfer Case Assembly Replacement (L84, L87 without F47) (1) — figure 34

53. Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.
54. Using the DT-35910 Drive Axle Seal Clamp Pliers (2), crimp the transfer case front output shaft boot clamp (3) until the gap (a) at the base of the ear is 1.5 mm (0.059 in).

Caution

Refer to Component Fastener Tightening Caution.

Note

A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers

55. Using a suitable tool, install and tighten the heated oxygen sensor bank 1 sensor 2 (1). Fastener Specifications

56. Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 2 » Connect

57. Fill the transfer case to the bottom of the fill plug hole with the recommended fluid. Transfer Case Fluid Replacement

58. Front Wheelhouse Liner - Left Side and Right Side (1) » Install — Front Wheelhouse Liner Replacement

59. Evaporative Emission Canister (1) » Install

60. Evaporative Emission Hose (2) » Connect [3x] — Plastic Collar Quick Connect Fitting Service

61. Evaporative Emission Canister Bracket Bolt (1) » Install and tighten — Fastener Specifications

62. Evaporative Emission Canister Bracket Nut (1) » Tighten [2x] — Fastener Specifications

63. Connect the battery negative cable. Battery Negative Cable Disconnection and Connection

64. After replacing the transfer case, perform the transfer case range actuator learn. Transfer Case Range Actuator Learn

65. Inspect for Leaks