Transfer Gear, Removing and Installing

5 SPD. A/T 01L AWD

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 fail 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
Transfer housing to rear transmission flange 23 Nm
Heat shield for drive shaft to transmission 23 Nm