TransferCaseRemovalandInstallationGuide

Item 1 2 3 4 5 6 7 8 9 Description Reardriveshaftbolt(4required) Reardriveshaft Frontdriveshaftbolt(4required) Frontdriveshaft Venthose Gearmotorencoderelectricalconnector Gearmotorelectricalconnector Transfercasetotransmissionbolt(11required) Transfercase

LiveDrivePlusKitIncludes:
1ModifiedTransferCase 1PTOtoShaftCoupling 132LongShaftwithKeys(35forRegularCab) 1SKFMountedBearing 20.5x1.25FlangeBolts 8OEMDriveshaftFlangeBolts 1Loctite242Threadlocker(MediumStrength),Blue,0.5ml 1Removal/InstallationManualandWarranty 2PTOShaftWarningLabels ReusablePackaging

RemovalInstructions
1. Shiftthetransfercaseto2H. 2. WiththevehicleinNEUTRAL,positionitonahoist. 3. Ifequipped,removethe4boltsandtheskidplate.

VehiclesEquippedwithFlangeCoupledDriveshaft 4. Removeanddiscardthe4frontdriveshaftboltsandpositionthefrontdriveshaftaside. 5. Removeanddiscardthe4reardriveshaftboltsandpositionthereardriveshaftaside. VehiclesEquippedwithSlipYokeDriveshaft 5.1. Removeanddiscardthe4reardriveshaftboltsandpositionthereardriveshaftaside. VehiclesEquippedwithManualShiftTransferCase 6. Disconnectthemanualshiftlinkagefromthetransmission. 7. Disconnectthe3positionmodeswitchelectricalconnector.

 VehiclesEquippedwithElectricShiftTransferCase 7.1. Disconnectthegearmotorencoderelectricalconnectorandthegearmotorelectrical connector.

AllVehicles 8. Disconnecttheventhose.

9. Moveventcapfrommodifiedtransfercasetooriginaltransfercase. 10. Supporttransmissionwithsuitablejackorundersling. 11. Removethetransmissionsupportcrossmember. 12. Positionasuitablehighlifttransmissionjacktothetransfercaseandsecureitwithsafety straps. 13. Removethe11transfercasebolts.Pullthetransfercaserearward,thenlowerthetransfercase fromthevehicle.

Note:PTOiseasiesttoinstallatthispoint,asforwarddriveshaftcanbemovedoutoftheway.

InstallationInstructions
1. Liftthenewtransfercaseintothevehicleandpushthetransfercaseforward. 2. Handtightenalltransfercasetotransmissionbolts.Torquetwoboltstospecificationthatare oppositeofeachotherfirst.Torqueeachboltslowlyinstepstoavoidbindingofthetransfer caseduringtightening.Afterthefirsttwoboltsaretorquedtospecification,nofurther tighteningsequenceisrequired. 3. Torque11boltsto40FTLB. 4. Removetransmissionjack. 5. Installthetransmissionsupportcrossmemberandtorqueto66FTLB. 6. Connecttheventhose. VehiclesEquippedwithManualShiftTransferCase 7. Connectthemanualshiftlinkagetothetransmission. 8. Connectthe3positionmodeswitchelectricalconnector. VehiclesEquippedwithElectricShiftTransferCase 8.1. Connectthegearmotorencoderelectricalconnectorandthegearmotorelectrical connector. VehiclesEquippedwithFlangeCoupledDriveshaft 9. Liftreardriveshaftintoposition.Install4newreardriveshaftboltsandtorqueto82FTLB. 10. Liftfrontdriveshaftintoposition.Install4newfrontdriveshaftboltsandtorqueto82FTLB. VehiclesEquippedwithSlipYokeDriveshaft 10.1. Insertthedriveshaftintothetransfercase.Install4newdriveshaftboltsandtorqueto 82FTLB AllVehicles 11. InstallFR66PTOperMuncieinstructions 12. Slipshaftthroughtransfercasefromback. 13. InstallPTOshaftcoupling.Applymediumstrengththreadlockertokeylockboltsandtorqueto 15FtLB 14. Slipmountedbearingoverendofshaftandbolttotransfercaseusingsuppliedbolts.Apply mediumstrengththreadlockertobearingretainerboltsandtorqueto85FtLB 15. FollowSKFinstruction(foundinbearingbox)totightenbearingcollartoshaft. 16. GreaseuniversaljointandSKFbearing. 17. Ifequipped,Installtheskidplateandtorquetheboltsto18FTLB. 18. Installwarninglabels.Placeontheoutsideofthevehicleframerail.Theselabelsaretobe easilyseenbyanyonewhomightgounderthetruckorneartheLiveDrivePLUS.Onelabelisto beplacedoneachsideofthevehicle.