Removing and Installing Transfer Case (Manual Transmission)

Note: After completion of work, check transmission oil level.




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!

Remove exhaust system.

Remove heat shield at rear.

Remove heat shield at front right.

Caution: Driving without reinforcement plate is not permitted.

Remove reinforcement plate.

Release stabilizer bar.

This operation is described in the section "Removing and installing front stabilizer", refer to Steering and Suspension.

Remove and install front propeller shaft.

Manual transmission





Support transmission with special tools 00 2 030 and 23 0 130.





Release screws and remove transmission cross-member.

Tightening torque, refer to Specifications.





Detach vent line (1).

Unclip cable from transfer case.





Release screws.

Tightening torque, refer to Specifications.

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.





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 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:





Note dowel sleeves.

Replace damaged dowel sleeves.

Apply a thin coat of grease to splines.

Grease: WEICON ANTISIZE.





Replace sealing ring (1) on drive shaft (2) of transfer case.