Transfer Case Replacement

Transfer Case Replacement

Removal Procedure

1. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Propeller Shaft Replacement).
2. Drain the oil from the transmission. Refer to Transmission Fluid Replacement ()
3. Remove the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNA) (Service and Repair)Front Wheel Drive Shaft Replacement - Right Side (GNB) (Service and Repair).
4. Remove the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (Service and Repair).
5. Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Bracket Replacement (Transmission Rear Mount Bracket Replacement)




6. Remove the support bracket fasteners (1)
7. Remove the support bracket to engine fasteners (2)
8. Support the transfer case with a suitable jack, and secure with suitable straps.




9. Remove the transfer case fasteners (3).
10. Lower and ease out the transfer case.

Installation Procedure

1. Clean the contact surfaces between the transfer case and the gearbox. Fit a new O-ring.
2. Raise and align the transfer case in the correct position in relation to the gearbox.





Caution: Refer to Fastener Caution (Fastener Caution).

3. Fit the transfer case. Tighten the bolts in the correct order as illustrated to 110 Nm (81 lb ft).
4. Fit the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.




5. Tighten the support bracket fasteners (1) to 5 Nm (44 lb in)
6. Tighten the support bracket to engine fasteners (2) to 60 Nm (44 lb ft)
7. Tighten the support bracket fasteners (1) to 60 Nm (44 lb ft).
8. Install the transmission rear mount bracket.
9. Install the drivetrain and front suspension frame. Refer to Drivetrain and Front Suspension Frame Replacement (Service and Repair)
10. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNA) (Service and Repair)Front Wheel Drive Shaft Replacement - Right Side (GNB) (Service and Repair).
11. Install the propeller shaft. Refer to Propeller Shaft Replacement (Propeller Shaft Replacement).
12. Fill the transmission with oil. Refer to Transmission Fluid Replacement ()