Mopar 68001932AA Transfer Case Rear Case

A transfer case rebuild is fairly complex for the 'shade tree mechanic,' involving dismantling many small intricate parts and reassembling them with close tolerances for mating shifter clearances, which may need the use of certain fit spacers and snap rings. Although it is possible to change the transfer case on your own, if you know basic car mechanics, the overhaul of the transfer case is best done by the transmission repair shop; an overhaul of the transfer case takes much time and is costly as compared to a rebuilt unit which can be purchased in the dealer parts departments and auto parts stores. Even new mechanics can pull off a transfer case rebuild provided they have proper tools used and provided they take their time in order not to miss equally important details. Instruments that would be require for the overhaul are internal and external snap-ring pliers, bearing puller, slide hammer, set of pin punches, dial indicator, hydraulic press if necessary besides a strong workbench and vise or transmission stand. Special attention should be paid to the documentation of the process of disassembling as the characteristics of how every component is disassembled, the relation of this component to the other parts, and the manner in which it is fixed should be described because this information is necessary when reassembling. Knowledge also of the area of the transfer case that is not working well helps in the assessment and replacement of its part.

Shift the transfer case to the neutral (N) position, then raise and support the vehicle. Place reference marks on the yokes and driveshafts for installation, and disconnect the front and rear driveshafts from the transfer case yokes. Drain the transfer case lubricant and support the transmission using a jack or similar device. Remove the skid plate, noting that on some automatic transmission models, the cross member may need to be removed to access the transfer case. Disconnect the transfer case electrical connectors, the vent tube from the transaxle, and the transfer case shift linkage or cable. Support the transfer case with another jack and secure it to the jack. Remove the nuts that secure the transmission to the transfer case, then separate the two components and remove the transfer case from the vehicle. Installation follows the reverse order of removal, ensuring to tighten the transfer case-to-transmission nuts to the specified torque. For 2006 and earlier models, adjust the shift linkage as necessary.