III. TRANSFER CASE REMOVAL
Removal from Vehicle
Remove fill and drain plugs and drain lubricant from
Tag wires leading to monitor light and disconnect
wires from transfer case.
Disconnect the air shift lines. Be sure to tag the lines
for future identification (air shift cases only).
Disconnect mechanical linkage and tag for future
identification (manual shift cases only).
Disconnect the speedometer cable if so equipped.
Disconnect drivelines at flanges or yokes.
Position a transmission jack of suitable capacity
beneath the transfer case (400 lb. transfer case). Be
sure that the transfer case is seated safely on the
Disconnect transfer case mountings at rubber
insulators. Since mountings vary, consult the vehicle
Check to ensure that all mountings and connections
to the transfer case have been disconnected. Lower
the transfer case to the floor and remove from under
Installation into Vehicle
Place transfer case on transmission jack and
position jack and transfer case under the vehicle.
Raise transmission jack and position transfer case.
Connect transfer case mountings. Since mountings
vary, consult the vehicle service manual.
Connect shift cylinder air lines to air cylinders.
Connect mechanical shift linkage to shift shafts.
Connect monitor light lead wires to terminals.
Fill transfer case housing with appropriate lubricant
to the correct level and install fill plug. If case is
equipped with a PTO, prime the PTO oil pump.
(Refer to Lubrication Section II especially paragraphs
C and H).
Road test the vehicle by driving slowly with no load
for the first few moments, then test at a higher speed
listening for any problems.
10. Check transfer case for leaks around gaskets and