Removal Procedure
- Raise the vehicle. Refer to Lifting and Jacking the Vehicle.
- Remove the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement.
- Disconnect the motor/encoder electrical connector (1).
- Remove the motor/encoder mounting bolts.
- Remove the motor/encoder assembly.
- Position the motor on a work bench.
- Release the 4 tabs that retain the motor/encoder plastic baseplate and remove the baseplate/gasket (1).
- Discard the old baseplate/gasket, replacement baseplate/gasket provided in rotary position sensor kit.
- Gently lift the motor/encoder rotary position sensor (2) from the motor shaft.
- Disconnect the rotary position sensor (2) from the wiring harness.
Note: When replacing the encoder rotary position sensor, follow steps 6-10. The rotary position sensor is circular with 3 contacts on one side and is positioned behind the motor/encoder baseplate/gasket. The rotary position sensor replacement kit consists of a rotary position sensor, baseplate/gasket, and detailed instruction sheet.
Note: The motor/encoder rotary position sensor internal wires go to a connector within the motor housing. This internal wire connector does not have a locking tab and is easily disturbed.
Note: Look at the motor/encoder housing (1) where the rotary position sensor was removed from. Take note of the "Hex" in the housing where the new sensor will seat when properly installed.
Installation Procedure
- Connect the wiring harness to the rotary position sensor.
- Gently insert a suitable tool along side the internal wires and press down on the internal wire connector to ensure the connector is fully installed.
- Properly align the keyway of the rotary position sensor with the motor/encoder shaft as indicated by the center reference line shown in the graphic.
- Ensure that the hex on the rotary position sensor (2) fits in the hex of the motor/encoder housing (3).
- Install the motor/encoder baseplate/gasket (1).
- Install the motor/encoder to the transfer case.
- Install motor/encoder mounting bolts to the transfer case and tighten to 16 N·m (12 lb ft).
- Connect the motor/encoder electrical connector (1).
- Install the fuel tank shield, if equipped. Refer to Fuel Tank Shield Replacement.
- Lower the vehicle. Refer to Lifting and Jacking the Vehicle.
Note: Provided the rotary position sensor was removed, follow steps 1-5 to install the sensor, otherwise proceed to step 6 installing the motor/encoder to the transfer case.
Note: When performing this service procedure, make sure that the motor/encoder unit is flat against the transfer case for proper installation.
Caution: Refer to Fastener Caution in the Preface section.
