Service Procedure

INSPECTION

^ Disconnect the cable at the negative battery terminal.

^ Raise and support vehicle on a hoist.

^ Remove skid plate if equipped.

^ Drain the transmission.

^ Disconnect the speedometer cable at the transfer case.

^ Separate the front propshaft from the transfer case. Move it away from the work area and secure it.

^ Remove the shift lever linkage from the transfer case.

^ Support transfer case with a suitable stand and remove bolts attaching it to the transmission adapter. Remove transfer case.

ADAPTER BORE DEPTH MEASUREMENT:

^ Measure the depth of the adapter bore. It should be 25 mm, (Figure No. 1). If the bore depth is less than 25 mm replace the adapter. Follow replacement procedure outlined below. If the bore depth is 25 mm reverse the above procedure to reinstall parts. Use a new gasket between the adapter and transfer case.
ADAPTER REPLACEMENT

^ Remove the adapter mount bolts from the crossmember. Lift and support the transmission so that the adapter can be removed.

^ Remove adapter from vehicle. Transfer mount to new adapter.

^ Using a new gasket install adapter to transmission.

^ Lower transmission and bolt mount to the crossmember.

^ Install transfer case to new adapter using a new gasket.

^ Connect transfer case to new adapter using a new gasket.

^ Connect transfer case shift linkage and speedometer cable.

^ Reinstall rear propshaft assembly.

^ Connect front propshaft.

^ Reinstall skid plate if removed.
^ Fill transmission with SAE-80W, or SAE-80W-90 GL-5 lubricant, approximately 4.0 quarts.

^ Lower vehicle.

^ Reconnect battery cable.

TORQUE SPECIFICATIONS:

Adapter to transfer case 33 N.m (24 lb ft)
Adapter to transmission 33 N.m (24 lb ft)
Adapter mount to crossmember 54 N.m (40 lb ft)
Skid plate to crossmember 63 N.m (46 lb ft)
Transmission filler plug 23 N.m (17 lb ft)
Rear propshaft front flange bolts 100 N.m (74 lb ft)
Propshaft to rear axle 33 N.m (24 lb ft)
Propshaft center bearing to hanger
bracket 33 N.m (24 lb ft)
Propshaft to transfer case 15 N.m (11 lb ft)

CAMPAIGN IDENTIFICATION LABEL:

CAMPAIGN IDENTIFICATION LABEL

Each vehicle corrected in accordance with the instructions outlined in this Product Campaign Bulletin will require a "Campaign Identification Label." Each label provides a space to include the five digit dealer code of the dealer performing the campaign service. This information may be inserted with a typewriter or ballpoint pen.
Each "Campaign Identification Label" is to be located on the radiator core support in an area which will be visible when the vehicle is brought in for periodic servicing by the owner.

Apply "Campaign Identification Label" only on a clean dry surface.