1

Transfer Case Intermediate Drive Shaft

2

Transfer Case Intermediate Drive Shaft Bearing Retainers (Qty: 2)

3

Transfer Case Intermediate Drive Shaft Bearing Assembly

Tip
Use a press, with the DT-22912-B/KM-307-B rear pinion and axle bearing remover flat side up, in order to install the bearing assembly.

Special Tools

DT-22912-B/KM-307-B Rear Pinion and Axle Bearing Remover

For equivalent regional tools, refer to Special Tools

4

O-ring

5

Half Shaft Retainer

1

Transfer Case Rear Output Shaft

2

Transfer Case Rear Output Shaft Bearing Spacer

3

Transfer Case Rear Output Shaft Housing

4

Transfer Case Rear Output Shaft Bearing Assembly

Tip
Use a press with the J-5590 pinion bearing race installer - rear to install the housing and bearings to the output shaft.

Special Tools

J-5590 Pinion Bearing Race Installer - Rear

For equivalent regional tools, refer to Special Tools

5

Transfer Case Rear Output Shaft Seal

Tip
Use a press with the DT-48075 output shaft seal installer to install the seal.

Special Tools

DT-48075 Output Shaft Seal Installer

For equivalent regional tools, refer to Special Tools

1

Transfer Case Rear Output Shaft Oil Slinger

Tip
Use a press with the DT-48077 output shaft slinger installer in order to install the slinger.

Special Tools

DT-48077 Output Shaft Slinger Installer

For equivalent regional tools, refer to Special Tools

2

Transfer Case Rear Output Shaft Flange

Tip
Use a press with the J-5590 pinion bearing race installer - rear to install the flange.

Special Tools

J-5590 Pinion Bearing Race Installer - Rear

For equivalent regional tools, refer to Special Tools

3

Transfer Case Rear Output Shaft Nut

Caution: Refer to Fastener Caution in the Preface section.

Tip

Tighten
235 N·m (173 lb ft)

Special Tools

DT-08614-A Pinion Flange Holder and Remover

For equivalent regional tools, refer to Special Tools

1

Transfer Case Half Locating Pins

2

Transfer Case Input Shaft

Tip
Install the input and output shafts as a set with the splines engaged.

3

Transfer Case Rear Output Drive Shaft

4

Transfer Case Seal to the Transfer Case - Right

5

Transfer Case - Right

6

Transfer Case Half Bolts (Qty: 12)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Transfer Case Rear Output Shaft Housing Seal O-ring

2

Transfer Case Rear Output Shim

3

Transfer Case Rear Output Shaft Housing

Caution: Do not use a drive hammer when the splines are not engaged. Use of a drive hammer when the splines are not engaged will damage the output shaft teeth.

Tip

Special Tools

EL-25070 Heat Gun - 500-750F

For equivalent regional tools, refer to Special Tools

4

Transfer Case Rear Output Shaft Housing Bolts (Qty: 6)

Caution: Refer to Fastener Caution in the Preface section.

Tighten
29 N·m (21 lb ft)

1

Front Wheel Drive Intermediate Shaft

Caution: DT-48094 must be used over the intermediate shaft prior to installation in order to protect the intermediate shaft seal from damage.

Special Tools

DT-48094 Installation Guide Shaft

For equivalent regional tools, refer to Special Tools

2

Front Wheel Drive Retainer

1

Transfer Case Input Shaft Face Seal - RPO MHC Only

2

Transfer Case O-ring Seal - RPO MH4 Only

3

Transfer Case Vent Assembly

Tip
Replace the vent if damaged or blocked.

4

Drain Plug

Caution: Refer to Component Fastener Tightening Caution in the Preface section.

Tighten
39 N·m (29 lb ft)

5

Fill Plug

Tighten
39 N·m (29 lb ft)

6

Transfer Case Heat Shield - Model Dependent

7

Transfer Case Heat Shield Bolts (Qty: 3) - Model Dependent

Caution: Refer to Fastener Caution in the Preface section.

Tighten
11 N·m (97 lb in)

8

Transfer Case Bracket

9

Transfer Case Bracket Bolts (Qty: 2)

Tip
Tighten the bracket bolts to light assembly torque. Tighten to specification after the transfer case is mounted in the vehicle. Refer to Fastener Tightening Specifications .