Service Information: Installation

Fig 1: Removing/Installing Transfer Case

Courtesy of DAIMLERCHRYSLER CORP.

1 - NV140 TRANSFER CASE

2 - NUTS

3 - TRANSMISSION

4 - TRANSFER CASE VENT TUBE

1. Mount transfer case on a transmission jack.
2. Secure transfer case to jack with chains.
3. Position transfer case under vehicle.
4. Align transfer case (1) and transmission (3) shafts and install transfer case onto the transmission. See Fig 1.
5. Install and tighten transfer case attaching nuts (2) to 35 N.m (26 ft. lbs.) torque.
6. Connect the transfer case vent hose (4).
7. Connect front propeller shaft and install rear propeller shaft. (Refer to DIFFERENTIAL & DRIVELINE/PROPELLER SHAFT/PROPELLER SHAFT - INSTALLATION)
   Fig 2: Fill/Drain Plug And I.D. Tag Locations

   Courtesy of DAIMLERCHRYSLER CORP.

   1 - I.D. TAG

   2 - FILL PLUG

   3 - DRAIN PLUG

8. Fill transfer case with correct fluid. (Refer to LUBRICATION & MAINTENANCE/FLUID TYPES - DESCRIPTION) Check transmission fluid level. (Refer to TRANSMISSION/AUTOMATIC - 45RFE/545RFE/FLUID - STANDARD PROCEDURE) Correct as necessary.
9. Install the transfer case fill plug (1). See Fig 2. Tighten the plug to 20-34 N.m (15-25 ft.lbs.).
10. Install rear crossmember and skid plate, if equipped. Tighten crossmember bolts to 41 N.m (30 ft. lbs.) torque.
11. Remove transmission jack and support stand.
12. Lower vehicle and verify transfer case shift operation.