Transfer Case Switch Replacement Instructions

[jac04]

Does anyone have the Factory Service Manual instructions for replacing the Transfer Case Switch 5083138AA? This is the switch located on top of the transfer case, looks like so:

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[Lunentucker]

It looks like you'd disconnect the cable, unscrew the old one, apply some Teflon tape, screw the new one in, reconnect the cable.

 

[jac04]

There is no Teflon tape - they are straight threads and there is a gasket seal.

I'm most interested to see what the FSM states regarding torque and if there is a factory tool for removal.

 

[Kevin_D]

I'm most interested to see what the FSM states regarding torque...

Tighten it 'til breaks and then back it off ¼ turn...
?

Kevin

 

[Lunentucker]

Then gob some rtv around it ?

 

[Lunentucker]

16-25 lb/ft.
https://www.extremeterrain.com/wrangler-jk-drivetrain-torque-specs.html

 

[jac04]

This is all interesting information, but ...

I'm looking specifically to see if anyone has the actual JT Factory Service Manual instructions for replacing the Transfer Case Switch 5083138AA.

I already have the JK FSM, but I want to know what the JT FSM states.

 

[Jeep78]

Bumping this thread. I have the factory service manuals and cannot find any instruction on how to replace this sensor without removing the transfer case. The sensor is very hard to get to and there is little clearance to the bottom of the cab. Seems like there would be a special tool required or maybe it’s easier to get at with the front driveshaft removed. Looking for any advice from someone who has done this job before.

 

[Hootbro]

Bumping this thread. I have the factory service manuals and cannot find any instruction on how to replace this sensor without removing the transfer case. The sensor is very hard to get to and there is little clearance to the bottom of the cab. Seems like there would be a special tool required or maybe it’s easier to get at with the front driveshaft removed. Looking for any advice from someone who has done this job before.

Every reference I have seen talks about it with the transfer case removed. Just one of those things

 

[jac04]

^^ Yup, the Factory Service Manual only addresses removing the position switch once the transfer case is removed.

It looks like you could get creative with an open end or box end wrench (i.e. bending it or cutting it as needed to make a removal tool).

 

[Badunit]

EDIT: Responding to the original post from a few years ago, not realizing it was from a few years ago...

Assuming "range position switch" and "transfer case position sensor" are the same thing, then 20 ft-lb. The following image is from '23 service manual.

 

[srmorse]

Hey all…I came upon this thread while looking to replace my switch and I wanted to advise I was able to do this without removing the transfer case. It was tight but manageable and only took 20-30 minutes. I was able to use a shallow 1 1/2” socket with 1/2” drive breaker bar. Note the shallow socket did not fully engage the entire head, but did not need to as not a ton of torque needed to loosen the old one.

hope this helps someone.

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