Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
Installation Procedure
Clean the contact surfaces between the power transfer unit case and the transmission.
- Install a NEW power transfer unit case-to-transmission O-ring (1).
Power Transfer Unit Half Shaft Seal (2) @ Power Transfer Unit - Install NEW
- Power Transfer Unit Half Shaft Retaining Ring (1) @ Power Transfer Unit - Install NEW
- CAUTION:
Use care when installing the transfer case assembly to avoid contact with the pinion spline. Contact with the pinion spline may cause damage to the transfer case assembly.
Support the power transfer unit case with a suitable jack, and secure with suitable straps.
- Raise and align the power transfer unit case in the correct position in relation to the transmission.
- Install the power transfer unit case (2) to the transmission.
- Install the power transfer unit case-to-transmission bolts (1) and tighten to - Fastener Specifications .
- Install the wheel drive half shaft to the power transfer unit. Turn the wheel drive half shaft back and forth to engage tangentially.
- NOTE:
Some components not shown for graphic clarity.
Transmission Mount Strut Bracket (2) - Install
- Transmission Mount Strut Bracket Bolt (1) - Install NEW and tighten [4x] - Fastener Specifications
Connect the electrical connectors (1), then install the wiring harness retainers (2) to the power transfer unit.
Transmission Brace (2) - Install
- Transmission Brace Bolt (1) - Install and tighten [2x] - Fastener Specifications
- NOTE:
Make sure bracket hole is aligned with transfer mount hole.
Starter Bracket - Install
- Starter Bracket Bolt (1) - Install and tighten - Fastener Specifications
- Install wiring harness retainers (2) as necessary.
Transmission Brace Bolt (1) - Install and tighten [3x] - Fastener Specifications
Generator heat shield (2) - Install
- Generator heat shield upper nut (1) - Install and hand tighten
Install Generator nut (1) lower and tighten upper and lower nuts. Fastener Specifications
- NOTE:
Correct fill level is 11 MM (0.43) Min below the fill plug hole.
Power Transfer Unit Heat Shield (2) - Install
- Power Transfer Unit Heat Shield Bolt (1) - Install and tighten [3x] - Fastener Specifications
- Check the power transfer unit case fluid level.
- Drivetrain and Front Suspension Cradle - Install - Drivetrain and Front Suspension Cradle Removal and InstallationDrivetrain and Front Suspension Cradle Removal and Installation
- Check transmission fluid level. Transmission Fluid Drain and Fill
- Power Transfer Unit Actuator Control Module: Programming and Setup. K47B Power Transfer Unit Actuator Control Module: Programming and Setup
Refer to Fastener 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.
NO RELATED
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.