Service Information: Installation

Fig 1: Transfer Case

Courtesy of DAIMLERCHRYSLER CORP.

1 - FILL PLUG

2 - INSPECTION PLUG

3 - DRAIN PLUG

4 - TRANSFER CASE

1. Support transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position the transfer case under the vehicle and align the input shaft with the transmission output shaft.
4. Move the transfer case and jack forward to engage transfer case to the transmission.
5. Install the nuts and bolts to attach transfer case to transmission. Tighten the 120mm bolts to 25 N.m (18 ft.lbs.), the 30mm bolts to 27 N.m (20 ft.lbs.), and the nuts to 20 N.m (15 ft.lbs.)
6. Raise the transmission and transfer case into their normal position.
7. Fill (1, 2) the transfer case with the appropriate fluid. See Figure.
8. Install the transfer case dampener.
   Fig 2: Transmission Mount Assembly - 3.5L

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TRANSFER CASE

   2 - TRANSMISSION MOUNT ASSEMBLY

   3 - BOLTS

9. Install the transmission mount assembly to the transfer case and install the bolts (3) to hold the transmission mount assembly (2) to the transfer case (1), 3.5L engine. Tighten the bolts to 55 N.m (41 ft.lbs.). See Fig 2.
   Fig 3: Transmission Mount - 5.7L

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - TRANSMISSION MOUNT

   2 - BOLTS

10. Install the transmission mount to the transfer case and install the bolts (2) to hold the transmission mount (1) to the transfer case, 5.7L engine. Tighten the bolts to 68 N.m (50 ft.lbs.). See Fig 3.
    Fig 4: Transmission Crossmember

    Courtesy of DAIMLERCHRYSLER CORP.

    1 - TRANSMISSION CROSSMEMBER

    2 - BOLTS

    3 - TRANSMISSION MOUNT

11. Install the bolts (2) to hold the transmission crossmember (1) to the transmission mount (3). Tighten the bolts to 65 N.m (48 ft.lbs.). See Figure.
12. Install the bolts to hold the transmission crossmember to the frame. Tighten the bolts to 68 N.m (50 ft.lbs.).
13. Install the front and rear propeller shafts to the transfer case. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT - INSTALLATION)