Removing and Installing Transfer Case (Automatic Transmission)

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





Filler plug (1): Tightening torque, refer to Specifications.

Fluid level to lower edge of filler plug.

Fill quantity.

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!

Move selector lever to park position "P".

Remove exhaust system.

Caution: Driving without reinforcement plate is not permitted.

Remove reinforcement plate.





Remove heat shields. Unclip cables for oxygen sensors.

Release stabilizer bar.

This operation is described in the section "Removing and installing front stabilizer".

Remove heat shield at rear.

Remove and install front propeller shaft.





Grip clamp bushing (1) and slacken nut (2).

Installation:
Adjust selector lever.





Grip cable (1) at hexagon (2).

Release nut (3).

Tightening torque, refer to Specifications.

Pull cable (1) out of holder.





Automatic transmission A5S 440Z (5HP24):

Support transmission with special tool 00 2 030 / 24 5 301, 24 0 250.





Automatic transmission A5S 36OR (GM5):

Support transmission with special tools 00 2 030 / 24 5 301 /24 5 305.





Unclip oxygen sensor cable at transmission cross-member.

Release screws and remove transmission cross-member.

Tightening torque, refer to Specifications.





Detach vent line (1).

Unclip oxygen sensor cable at transfer case.





Release screws.

Tightening torque, refer to Specifications.

Installation:
Replace self-locking nuts.

Only tighten screw connection by way of nut.

This prevents the flexible disk from being subjected to torsion stress.





Grip propeller shaft at center mount and release nuts.

Tightening torque, refer to Specifications.

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





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





Bend propeller shaft downwards at center mount.

Remove propeller shaft from transmission output flange and tie back to one side with cord or wire.





Take up transfer case with special tools 27 1 100 and 00 2 030.

Release transfer case screw connection on transmission.

Tightening torque, refer to Specifications.

Remove transfer case.

Installation:





Pay attention to dowel sleeves.

Replace damaged dowel sleeves.

Apply a thin coat of grease to splines.

Grease: WEICON ANTISIZE.