Page 4169 of 5267
BOOT-EXTENSION HOUSING SEAL AND DUST
REMOVAL
1. Raise and support vehicle.
2. Remove rear propeller shaft. (Refer to 3 - DIFFER-
ENTIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - REMOVAL)
3. Use a suitable chisel or pry tool to remove the rear
extension housing dust boot (2).
4. Use a suitable chisel or pry tool to remove the rear
extension housing seal.
INSTALLATION
1. Clean fluid residue from sealing surface and
inspect for defects.
2. Install the extension housing dust boot and seal
assembly with Seal Installer 9037 (3) and Universal
Handle C-4171 (2).
3. Install propeller shaft. (Refer to 3 - DIFFERENTIAL
& DRIVELINE/PROPELLER SHAFT/PROPELLER
SHAFT - INSTALLATION)
4. Verify proper transfer case fluid level.
5. Lower vehicle.
Page 4170 of 5267
FLUID
STANDARD PROCEDURE - FLUID DRAIN AND REFILL
The fill (1) and drain (2) plugs are both in the rear
case.
1. Raise vehicle.
2. Position drain pan under transfer case.
NOTE: It may be necessary to remove the exhaust
y-pipe at the exhaust manifold to properly access
the fill and drain plugs. Lowering the exhaust will
allow the plugs to be accessed for torquing during
installation. (Refer to 11 - EXHAUST SYSTEM/EX-
HAUST PIPE - REMOVAL)
3. Remove drain and fill plugs and drain lubricant
completely.
4. Install drain plug. Tighten plug to 41-54 Nꞏm (30-40
ft. lbs.).
5. Remove drain pan.
6. Fill transfer case to bottom edge of fill plug opening
with Mopar
ATF +4, Automatic Transmission fluid.
7. Install and tighten fill plug to 41-54 Nꞏm (30-40 ft. lbs.).
8. Install the exhaust y-pipe to the exhaust manifold, if removed. (Refer to 11 - EXHAUST SYSTEM/EXHAUST
PIPE - INSTALLATION)
9. Wipe any excess fluid that may have spilled onto the exhaust.
10. Lower vehicle.
Page 4171 of 5267

SEAL-FRONT OUTPUT SHAFT
REMOVAL
1. Remove the front propeller shaft (Refer to 3 - DIF-
FERENTIAL & DRIVELINE/PROPELLER SHAFT/
PROPELLER SHAFT - REMOVAL).
2. Install two bolts 180° apart into the front output
shaft companion flange.
3. Place Yoke Holder 6719 (1) over the bolts (2) and
against the companion flange.
4. Remove and discard the front companion flange
nut.
5. Remove the companion flange from the front out-
put shaft. It may be necessary to use Pinion
Flange Remover 8992 to remove the companion
flange.
6. Using a screw and a slide hammer, remove the
front output shaft seal.
INSTALLATION
1. Install the new front output shaft seal with Seal
Installer MB991168A.
2. Install the front companion flange onto the front
output shaft.
3. Install two bolts 180° apart into the front output
shaft companion flange.
4. Place Yoke Holder 6719 (1) over the bolts (2) and
against the companion flange.
5. Install a new front companion flange nut. Tighten
the companion flange nut to 258-312 Nꞏm (190-230
ft.lbs.).
6. Install front propeller shaft (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/PROPELLER SHAFT/PRO-
PELLER SHAFT - INSTALLATION).
Page 4172 of 5267

SENSOR-POSITION
DESCRIPTION
The transfer case position sensor is an electronic device whose output canbe interpreted to indicate the transfer
case’s current operating mode. The sensor consists of a five position, resistive multiplexed circuit which returns a
specific resistance value to the Powertrain Control Module (PCM) for eachtransfer case operating mode. The sen-
sor is located on the top of the transfer case, just left of the transfer casecenterline and rides against the sector
plate roostercomb. The PCM supplies 5VDC (+/- 0.5V) to the sensor and monitors the return voltage to determine
the sector plate, and therefore the transfer case, position.
OPERATION
Operating Mode Versus Resistance
SENSOR POSITION OPERATING MODE SENSOR RESISTANCE (ohms)
1 2H 1172-1195
24H677-691
3 NEUTRAL 406-415
44L208-213
5 NOT USED 60-61
During normal vehicle operation, the Powertrain Con-
trol Module (PCM) monitors the transfer case position
sensor return voltage to determine the operating mode
of the transfer case. Refer to the Operating Mode Ver-
sus Resistance table for the correct resistance for
each position.
REMOVAL
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the positionsensor.
3. Remove the position sensor from the transfer case.
Position Sensor Linear Movement
1 - POSITION 1 - 10mm ±0.5mm
2 - POSITION 2 - 12mm ±0.5mm
3 - POSITION 3 - 14mm ±0.5mm
4 - POSITION 4 - 16mm ±0.5mm
5 - POSITION 5 - 18mm ±0.5mm
6 - POSITION 6 - 20mm±0.5mm - FULL EXTENSION
Page 4173 of 5267
INSTALLATION
1. Inspect the o-ring seal on the transfer case position sensor. Replace the o-ring if necessary.
2. Install the transfer case position sensor into the transfer case. Torque the sensor to 27 Nꞏm (20 ft.lbs.).
3. Engage the transfer case position sensor connector to the position sensor.
4. Lower vehicle.
5. Verify proper sensor operation.
Page 4174 of 5267
LEVER-SHIFT
REMOVAL
1. Shift transfer case into 2H.
2. Raise and support the vehicle.
3. Loosen adjusting trunnion lock bolt and slide shift rod out of trunnion.If rod lacks enough travel to come out of
trunnion, push trunnion out of shift lever.
4. Lower vehicle.
5. Remove transfer case shifter knob cap.
6. Remove nut holding shifter knob (2) to shift lever.
7. Remove shifter knob.
8. Remove the shift boot from the shifter console.
9. Remove the bolts securing the shifter mechanism to the floor pan.
10. Separate shift lever mechanism from the vehicle.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
Page 4175 of 5267

INSTALLATION
1. If the shifter mechanism does not have a adjustment locating pin installed, align the adjustment channel on the
shifter assembly to the locating hole in the lower shift lever and install an appropriately sized pin to retain the
position.
2. Position shift lever in vehicle.
3. Install the bolts to hold the shifter mechanism (4) to the floor pan.
4. Raise vehicle.
5. Verify that the transfer case is still in the 2H position. The 2H detent position on the transfer case shift arm is the
second position from full forward.
6. Install trunnion to shift lever, if necessary.
7. Install shift rod to trunnion, if necessary.
8. Tighten the shift rod lock bolt to 10 Nꞏm (90 in.lbs.).
9. Remove the shifter adjustment locating pin from the adjustment channeland the locating hole.
10. Lower vehicle.
11. Install the transfer case shifter console.
12. Install the shifter boot and the shifter knob onto the shifter lever.
13. Install nut to hold shifter knob to shift lever.
14. Install shifter knob cap.
15. Verify transfer case operation.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE
Page 4176 of 5267

ADJUSTMENTS
ADJUSTMENT - SHIFT LEVER
1. Move shift lever into 2H position.
2. Raise vehicle.
3. Loosen shift rod lock bolt at trunnion.
4. Check shift rod fit in trunnion. Be sure rod does not bind in trunnion. Lubricate the shift rod and trunnion if nec-
essary.
5. Verify that transfer case shift lever is in 2H detent position. The 2H detent position on the transfer case shift arm
is the second position from full forward.
6. Align the adjustment locating hole on the lower shifter lever with the adjustment channel on the shifter bracket
assembly.
7. Insert an appropriately sized pin through into the adjustment channel and through the locating hole to hold the
shifter in the correct position.
8. Tighten shift rod lock bolt to 10 Nꞏm (90 in. lbs.) torque.
9. Remove the locating pin from the adjustment channel and locating hole.
10. Check shift linkage operation. Be sure transfer case shifts into and operates properly in all ranges.
Transfer Case Shifter
1 - SHIFTER BOOT 4 - SHIFTER MECHANISM
2-SHIFTERKNOB 5-ALIGNMENTPIN
3 - SHIFTER CONSOLE 6 - TRANSFER CASE