### Transfer Case Assembly

#### REMOVAL & INSTALLATION

1. Remove the transmission and transfer case assembly from the vehicle.

   NOTE: Have a pan ready to catch any spilt fluid.

2. Remove the bolt attaching the speedometer driven gear cable and set the cable aside.
3. If necessary, disconnect and remove the No. 1 and No. 2 speed sensors.
4. If necessary, remove the speedometer driven gear.

   Fig. 1: Disengage the cable from the driven gear

   Fig. 2: Remove the driven gear if necessary

5. Unbolt the transfer from the transmission.
6. If necessary, remove the transfer adapter. Remove the six bolts and the adapter. It may be necessary to tap the adapter with a plastic hammer to loosen it. Discard the gasket.

   To install:

7. If removed, install the transfer adapter with a new gasket. Apply sealant such as Three bond 1344 or Locktite 242 or equivalent. Tighten the bolts to 25 ft. lbs. (34 Nm).
8. Attach the transfer case to the transmission. Tighten the bolts to 27–37 ft. lbs. (36–50 Nm).
9. Attach the speedometer cable and tighten the bolt to 33 ft. lbs. (45 Nm).
10. If removed, install the speedometer gear and the No. 1 and No. 2 speed sensors.
11. Replace any necessary seals or gaskets. Install the transfer/transmission assembly into the vehicle.