Installation Procedure
- Clean the contact surfaces between the transfer case and the transmission.
Power Transfer Unit Interface Seal (1) - Install NEW
Support the transfer case with a suitable jack, and secure with suitable straps.
- Raise and align the transfer case in the correct position in relation to the transmission.
- Install the transfer case (2) to the transmission.
- Power Transfer Unit Bolt (1) Install and tighten [3x] - Fastener Specifications
Connect the transfer case vent hose (1) to the transfer case (2).
Power Transfer Unit Bolt (1) Install and tighten [2x] - Fastener Specifications
- Connect the shift actuator electrical connector.
Transfer Case Bracket (3) - Install
- Transfer Case Bracket Bolt (2) - Install and tighten [2x] - Fastener Specifications
- Transfer Case Bracket Bolt (1) - Install and tighten [3x] - Fastener Specifications
Clean the splines of the power transfer unit output shaft and apply a light coat of high temperature grease. Adhesives, Fluids, Lubricants, and Sealers
- Power Transfer Unit Half Shaft Seal (2) - Install NEW
- Front Wheel Drive Shaft Retaining Ring (1) - Install NEW
- Prior to installation, clean the splines of the wheel drive shaft constant velocity inner joint and apply a light coating of high temperature grease. Adhesives, Fluids, Lubricants, and Sealers
Front Wheel Drive Shaft Washer (1) @ Front Wheel Drive Half Shaft - Install NEW
- NOTE:
Ensure that the front wheel drive half shaft is fully seated onto the power transfer unit.
Front Wheel Drive Half Shaft (1) - Install
- Install the front wheel drive half shaft (1) into the front wheel hub.
- CAUTION:
This vehicle is equipped with torque-to-yield or single use fasteners. Install a NEW torque-to-yield or single use fastener when installing this component. Failure to replace the torque-to-yield or single use fastener could cause damage to the vehicle or component.
Front Wheel Drive Shaft Nut (1) - Install NEW and hand tighten
- Have an assistant apply the brakes.
- Front Wheel Drive Shaft Nut (1) - Tighten - Fastener Specifications
Power Transfer Unit Heat Shield (2) - Install
- Power Transfer Unit Heat Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
Turbocharger Exhaust Pipe Gasket (2) - Install NEW
- Warm Up Three-Way Catalytic Converter (1) - Install
Catalytic Converter Brace Bracket Bolt (1) - Install and hand tighten [2x]
- Connect the electrical connector.
Warm Up Three-Way Catalytic Converter Nut. (1) - Install and tighten [4x] - Fastener Specifications
Catalytic Converter Brace Bracket Bolt (1) - Tighten [2x] - Fastener Specifications
Catalytic Converter Front Heat Shield- Inner (1) - Install
Turbocharger Heat Shield Bolt (1) - Install and tighten [2x] - Fastener Specifications
Catalytic Converter Front Heat Shield- Outer (1) - Install
- NOTE:
Using a torque adapter may be helpful for bolt access.
Turbocharger Heat Shield Bolt (1) - Install and tighten [4x] - Fastener Specifications
- CAUTION:
Refer to Component Fastener Tightening Caution .
NOTE:A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled, the threads must have anti-seize compound applied before reinstallation. Adhesives, Fluids, Lubricants, and Sealers
Using a suitable tool, install and tighten the heated oxygen sensor (1). Fastener Specifications
- Connect the electrical connector.
Drivetrain and Front Suspension Cradle (1) - Install - Drivetrain and Front Suspension Cradle Removal and Installation (AWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (FWD) , or Drivetrain and Front Suspension Cradle Removal and Installation (Z71)
- Refill power transfer case fluid. Power Transfer Unit Case Fluid Replacement
- Inspect the exhaust system for leaks.
Refer to Fastener Caution .
Do NOT use air tools to tighten the front wheel drive shaft nut. Tighten the NEW front wheel drive shaft nut slowly to draw the front wheel drive half shaft into the front wheel hub prior to tightening to specifications.