Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Transfer Case - Vehicles With: 2-Speed Torque On Demand Transfer Case: Assembly
- Remove the contamination and deposits from the transfer case housing and cover using a plastic scraper. Clean the transfer case housing and cover using a soft bristle brush to remove the contamination. Clean any remaining lip seal coating that may still be present on the housing or cover bores with a wire brush. Make sure the vent fitting and housing pockets are clean and clear.
Use the General Equipment: Spatula
- Clean the transfer case housing and cover flange sealing surfaces. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Using the special tools, install the shift shaft seal.
Use Special Service Tool: 307-549 Installer, Shift Shaft Fluid Seal.
- Using the special tool, install the front output shaft support bearing.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
- Using the special tool, install the rear output shaft bearing.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 307-582A Cover Axle Seal Installer.
- Using the special tools, install the front planet carrier bearing.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-504 Installer, Halfshaft Pilot Bearing.
- Using the special tools, install the front output shaft bearing.
Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-293 (T89P-4850-A) Installer, Differential Oil Seal.
- Using the special tool, install the front output shaft seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
- Using the special tool, install the input shaft seal.
Use Special Service Tool: 308-250 (T96T-7127-B) Installer, Output Shaft Oil Seal.
- Install the front output shaft.
- Install the front output shaft dust cover.
- Install the ring gear.
- If removed, using a press and the special tool, install the needle bearing into the front planet carrier.
Use Special Service Tool: 308-085 (T83T-7025-C) Installer, Input Shaft Bearing.
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NOTE: Replace the inner planet carrier needle bearing if necessary.
Install the front planet carrier.
- Install the ring gear circlip.
- Install the planet carrier thrust bearing.
- Install the electric shift cam assembly.
- Install the reduction hub.
- Install the output shaft.
- Install the shift fork.
- Install the shift rail.
- Install the oil pump assembly.
- Install the magnet into its slot in the case.
- Install the thrust bearing assembly.
- Install the thrust washer.
- Install the thrust bearing.
- Install the thrust washer.
- Install the drive chain and the sprockets as an assembly.
- Install the output shaft sprocket spacer.
- Install the clutch pack spacer.
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NOTE: When installing the clutch assembly, do not separate the clutch pack assembly. The thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance problem will occur.
NO RELATED
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.