Transfer Gear, Removing and Installing

Transfer gear, removing and installing
Removing
- Disconnect left and right three way catalytic converters from rear exhaust system and press both three way catalytic converters apart at rear.
- If necessary, remove rear part of the exhaust system.
- Remove heat shield for drive shaft.
- Remove driveshaft from transmission flange
- Place drip tray underneath transfer case.
- Drain transmission fluid from transfer case





- Loosen mounting bolts (arrows) for transfer housing in diagonal sequence and remove.

CAUTION! Slowly and carefully pull transfer case housing for front final drive off of transfer case toward rear. Otherwise the Torsen differentials can fall out of the transfer case.





- Press Torsen differential (complete) to rear, off output pinion (in direction of arrow).

Installing
Installation is the reverse of removal. Also carry out the following procedure:
- Check for presence of dowel sleeves (arrows -A- and -B-).
- Install gasket.

Note: Apply a thin coat of Vaseline on sealing surface -D- before installing gasket to avoid slipping of the gasket.





- Slide cleaned magnets into cast holding pocket-1- in intermediate flange.





- Slide Torsen differential (complete) onto splines of output shaft and bottom spur gear (in direction of arrow).

Note:
^ Turn differential slightly when installing to ensure damage-free engagement of the splines.
^ Check that Torsen differential can be turned by hand when it is in position.





- Install fully assembled transfer housing with installed front gears and rear drive flange onto transmission.
- Insert mounting bolts for transfer housing and tighten by hand, then bring to final torque by tightening in diagonal sequence.

Note: When tightening bolts by hand, make sure the housing gap between transfer housing and transmission housing decreases evenly around circumference.

- Check and top off transmission fluid in transfer case.





Tightening torques