Transfer Case Assembly Replacement (LM2 without F47) (1)

Transfer Case Assembly Replacement (LM2 without 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

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 - Right Side » Remove — Front Wheelhouse Liner Replacement

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 1

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 2

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 3

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 4

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 5

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 6

11. Exhaust Pipe Clamp (1) » Loosen

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 7

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 8

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 9

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 10

16. Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft » Remove and DISCARD
17. 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 without F47) (1) — figure 11

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 12

21. Front Axle Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 13

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 14

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 15

26. Propeller Shaft (1) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 16

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 17

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 18

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 19

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 20

33. Transmission Support Crossmember (1) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 21

34. Transmission Mount Bolt (1) » Remove [2x]
35. Transmission Mount (2) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 22

36. Disconnect the wiring harness retainers.
37. Catalytic Converter Brace Bracket Bolt (1) » Remove [2x]
38. Exhaust Front Bracket (2) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 23

39. Transmission Heat Shield Bolt (2) » Remove
40. Transmission Heat Shield Bolt (1) » Remove [2x]
41. Transmission Heat Shield (3) » Remove

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 24

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 25

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 26

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

49. Transfer Case (2) » Remove

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

51. Disconnect the wiring harness retainers. Installation Procedure

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

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

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

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

28. Remove the transmission jack.

29. Propeller Shaft (3) » Install

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 27

30. Align the reference marks made between the rear wheel drive shaft flange and the front and rear propeller shaft (2).
31. 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: 31.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 31.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 31.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 31.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.
32. Install the 4 rear propeller shaft bolts (1) and tighten in a crisscross pattern. Fastener Specifications

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 28

33. Transfer Case Front Output Shaft Boot (1) » Install
34. 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 without F47) (1) — figure 29

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

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

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

38. Front Axle Propeller Shaft (3) » Install

39. 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: 39.1. Remove any loose cured adhesive from the external threads of the components using a lint free cloth. 39.2. Thread the cleaned components into the internal mating threads and remove to loosen trapped cured adhesive. 39.3. Apply thread locking adhesive to the external threads of the components. Adhesives, Fluids, Lubricants, and Sealers 39.4. Ensure there are no gaps in the thread locking adhesive once applied to the component.

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

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

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

Transfer Case Assembly Replacement (LM2 without F47) (1) — figure 30

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

44. 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).

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

46. Nitrogen Oxides Catalytic Converter (1) » Install

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

48. Catalytic Converter Brace Bracket (3) » Install

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

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

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

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

53. 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.

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

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

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

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

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

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

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

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

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

63. Inspect for Leaks