Removal and Installation

Remove Transfer Case





Note: After completing work, check transmission fluid level and top up if necessary.

Filler plug (1):


Fluid level to lower edge of filler plug.

Fill quantity, refer to specifications.

Caution: Use only the approved transmission fluid in this transfer case.

Failure to comply with this requirement will result in serious damage to the transfer case!

Remove underbody protection.

Remove exhaust system.

Remove heat shield at rear.

Remove heat shield at front right.

Remove front propeller shaft.





Manual transmission S5D 32OZ.,
Support transmission with special tools 00 2 030 and 230140.





Automatic transmission A5S 360R (GM5):
Support transmission with special tools 00 2 030 and 24 5 301/305.





Release screws and remove transmission cross-member (1).


Detach vent line (1).





Release screws.


Installation:
Replace self-locking nuts.

When tightening screws down: Grip each screw and tighten down nut, This prevents the flexible disk from being subjected to torsion stress.





Caution: Do not let propeller shaft fall into joints. Joints and rubber sleeve can be damaged on constant-velocity joint.





Grip propeller shaft firmly at center mount (1) and release nuts.
Tightening torque, Center mount = 21 Nm.

Bend propeller shaft downwards at center mount (1).
Detach propeller shaft from transmission output flange and tie back to side on vehicle underbody.

Installation:
Center mount must be aligned at right angles to propeller shaft.

Release transfer case screw connection on transmission.
Tightening torque, Transfer case to trans. M10 = 43 Nm.

Remove transfer case.





Installation:
Pay attention to dowel sleeves.
Replace damaged adapter sleeves.

Apply a thin coat of grease to splines.
Grease: WEICON ANTISIZE.





Manual transmission:
Replace sealing ring (1) on drive shaft (2).