Things You'll Need:
- Socket set
- End wrench set
- Transmission jack (or a floor jack)
- Automatic transmission fluid
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Step 1
Lift the case up to the transmission. The first key to a successful install is to not attempt it alone. Get a few friends over and do it safely, because transfer cases are extremely heavy. It is best to place the transfer case on a transmission jack so that it can get up to the bellhousing easier, but a regular floor jack with blocks of 4 inch by 4 inch wood will normally do the trick. Center the transfer case on the vehicle while at least two people hold it in place on the jack, and slowly lift it up to its home in the Cherokee.
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Step 2
Bolt the transfer case to the bellhousing once it is lined up. It is recommended to follow the manufacturer's specifications as far as bolt torque, but the goal is to get them as tight as you can. There may need to be some slight adjustments to the case (clockwise or counterclockwise rotation) to get it to slide in on the output splines. These adjustments and the weight of the case are why the job shouldn't be attempted alone.
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Step 3
Hook up the drive shafts and shifting linkage, and fill the transfer case with fluid. Both the front and rear drive shafts connect to the case using U-joints. The shifting linkage can be found near the top of the driver side of the case, and it just bolts on to connect it. The speedometer cable also screws into the transfer case near the top, so don't forget that or your speedometer will always read zero.
