Transfer Case Assembly Replacement (LM2 with F47) (1)

Transfer Case Assembly Replacement (LM2 with F47) Single Use Fasteners and Components Exhaust System Front Gasket 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

If the air lines need to be removed to perform repairs on any air suspension components, depressurize the Automatic Level Control System. This will prevent vehicle damage or personal injury.

Warning

Do NOT remove Automatic Level Control System components under any circumstances when the system is pressurized. Disconnecting a pressurized air line that is connected to an Automatic Level Control System component can cause damage to components or personal injury.

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.

Caution

After servicing Automatic Air Suspension Leveling System, use Nitrogen to recharge the system. Using compressed air can expose the Automatic Air Suspension Leveling System components to moisture and or dirt resulting in premature wear requiring unnecessary repairs. Removal Procedure

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 1

5. Exhaust Front Pipe Nut (1) » Remove [2x]

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 2

6. Catalytic Converter Brace Bracket Nut (1) » Remove [2x]
7. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Remove
8. Catalytic Converter Brace Bracket (3) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 3

9. Using a suitable tool, remove the position 2 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 4

10. Using a suitable tool, remove the position 3 nitrogen oxides sensor (1) from the nitrogen oxides catalytic converter.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 5

11. Using a suitable tool, remove the exhaust particulate matter sensor (1) from the nitrogen oxides catalytic converter.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 6

12. Exhaust Pipe Clamp (1) » Loosen

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 7

13. Exhaust Front Pipe Nut (1) » Remove [2x]

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 8

14. Nitrogen Oxides Catalytic Converter (1) » Remove
15. Exhaust System Front Gasket (2) » Remove and DISCARD

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 9

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 10

17. Unclip the 2 air line retainers (1) and reposition the air line (2).

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 11

18. If equipped, remove the chassis wire harness clip (1) from the automatic level control air supply reservoir.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 12

19. Remove the 3 automatic level control air compressor bolts (1).
20. Automatic Level Control Air Supply Reservoir (2) » Reposition

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 13

21. Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft » Remove and DISCARD
22. 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 (LM2 with F47) (1) — figure 14

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 15

26. Front Axle Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 16

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 17

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 18

31. Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 19

32. Fuel Heater Inlet and Outlet Bolt (1) @ Transmission Support Crossmember » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 20

33. Remove the 4 wiring harness retainers (3), then reposition the wiring harness as necessary.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 21

34. Transmission Mount Nut (1) » Remove [2x]
35. Support the transmission with a suitable jack.

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 22

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 23

38. Transmission Support Crossmember (1) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 24

39. Transmission Mount Bolt (1) » Remove [2x]
40. Transmission Mount (2) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 25

41. Disconnect the wiring harness retainers.
42. Catalytic Converter Brace Bracket Bolt (1) » Remove [2x]
43. Exhaust Front Bracket (2) » Remove

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 26

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 (LM2 with F47) (1) — figure 27

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 28

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 29

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

54. Transfer Case (2) » Remove

55. Transfer Case Adapter Gasket (3) » Remove and DISCARD

56. Disconnect the wiring harness retainers. Installation Procedure

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

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

59. Transfer Case (2) » Install

Caution

Refer to Fastener Caution.

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

5. Connect the wiring harness retainers.

6. Remove the transmission jack from the transfer case.

7. Transfer Case Vent Hose (1) » Install

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

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

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

11. Transmission Heat Shield (3) » Install

12. 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: 12.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 12.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 12.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 12.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

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

15. Exhaust Front Bracket (2) » Install

16. Catalytic Converter Brace Bracket Bolt (1) » Install and tighten [2x] — Fastener Specifications

17. Connect the wiring harness retainers.

18. Transmission Mount (2) » Install

19. 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: 19.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 19.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 19.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 19.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

21. Transmission Support Crossmember (1) » Install

22. Transmission Support Crossmember Bolt (2) » Install [4x]

23. Transmission Support Crossmember Nut (1) » Install and tighten [4x] — Fastener Specifications

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

25. Remove the support from the transmission.

26. Automatic Level Control Air Supply Reservoir (2) » Install

27. Install the 3 automatic level control air compressor bolts (1) and tighten. Fastener Specifications

28. Install the chassis wire harness clip (1) to the automatic level control air supply reservoir.

29. Install the air line (2) and clip the 2 air line retainers (1).

30. Install the wiring harness as necessary and connect the 4 wiring harness retainers (3).

31. Fuel Heater Inlet and Outlet Bolt (1) @ Transmission Support Crossmember » Install and tighten — Fastener Specifications

32. Remove the transmission jack.

33. Propeller Shaft (1) » Install

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

35. 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: 35.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 35.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 35.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 35.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 30

37. Transfer Case Front Output Shaft Boot (1) » Install
38. 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 (LM2 with F47) (1) — figure 31

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

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

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

42. Front Axle Propeller Shaft (3) » Install

43. 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: 43.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 43.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 43.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 43.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

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

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

Transfer Case Assembly Replacement (LM2 with F47) (1) — figure 32

47. Ensure the transfer case front output shaft boot (1) is fully engaged into the groove of the transfer case front output shaft.

48. 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).

49. Exhaust System Front Gasket (2) » Install NEW

50. Nitrogen Oxides Catalytic Converter (1) » Install

51. Exhaust Front Pipe Nut (1) » Install and tighten [2x] — Fastener Specifications

52. Catalytic Converter Brace Bracket (3) » Install

53. Wiring Harness Retainer (2) @ Catalytic Converter Brace Bracket (3) » Install

54. Catalytic Converter Brace Bracket Nut (1) » Install and tighten [2x] — Fastener Specifications

55. Exhaust Front Pipe Nut (1) @ Catalytic Converter Brace Bracket » Install and tighten [2x] — Fastener Specifications

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

57. Coat the threads of the exhaust particulate matter sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

Caution

Refer to Component Fastener Tightening Caution.

58. Using a suitable tool, install and tighten the exhaust particulate matter sensor (1). Fastener Specifications

59. Coat the threads of the position 3 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

60. Using a suitable tool, install and tighten the position 3 nitrogen oxides sensor (1). Fastener Specifications

61. Coat the threads of the position 2 nitrogen oxides sensor (1) with anti-seize compound. Adhesives, Fluids, Lubricants, and Sealers

62. Using a suitable tool, install and tighten the position 2 nitrogen oxides sensor (1). Fastener Specifications

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

64. Front Wheelhouse Liner - Right Side » Install — Front Wheelhouse Liner Replacement

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

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

67. Inspect for Leaks

68. Take the air system out of service mode.