1 20-3. TRANSFER CASE REPLACEMENT
This task covers:
General mechanics tool kit:
automotive (Appendix B, Item 1)
Torque adapter, 9/16-in.
(Appendix B, Item 133)
Six locknuts (Appendix G, Item 172)
Four lockwashers (Appendix G, Item 206)
Cotter pin (Appendix G, Item 27)
Anaerobic gasket sealer
(Appendix C, Item 58)
l Muffler and catalytic converter removed
l Mumer support bracket removed (para. 3-55).
General Safety Instructions
l Allow transfer case to cool before performing
l Transfer case must be supported during removal
(4) from transfer case (1). Allow fluid to drain and install drainplug (4). Tighten
drainplug (4) to 35 lb-ft (47 Nom).
Remove four nuts (12), lockwashers (13), two U-bolts (14), and front propeller shaft (15) from
transfer case yoke (11). Discard lockwashers (13).
Disconnect vent line (5) from adapter (8) on transfer case (1).
Disconnect 90 speedometer cable adapter (7) from transfer case (1) and remove cable adapter (7)
with speedometer cable (6).
Remove rear propeller shaft (3) from transfer case housing (2).
Loosen two hose clamps (9) and disconnect rubber cooling lines (10) from transfer case (1).
Allow transfer case to cool before performing this task. Failure to
do this may cause injury to personnel.
Cover or plug all open lines and connections immediately after
disconnection to prevent contamination. Remove all plugs prior to