Transfer Case: Service and Repair

Transfer Case Assembly Replacement

Removal Procedure

1. Raise and support the vehicle.
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement .
3. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill .
4. Remove the propeller shaft. Refer to Propeller Shaft Replacement Service and Repair.
5. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement Service and Repair.
6. Remove the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement Service and Repair.
7. Support the transaxle with a jackstand.
8. Remove the engine rear mount bracket. Refer to Engine Rear Mount Bracket Replacement Service and Repair.






9. Remove the transfer case bolts (1).
10. Remove the transfer case (2).

Installation Procedure






1. Lubricate the O-rings (2, 3) with automatic transmission fluid.
2. Install the NEW transfer case O-ring seal (3).






Note: Oxidation must be removed from the transmission torque converter housing bore before installation of the transfer case. A clean bore will prevent oxidation build up from scuffing or cutting the O-ring seal upon transfer case installation, resulting in a leak.

3. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
4. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
5. Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.






Note: Use guide pins to aid in alignment and installation of the transfer case to the transmission. Failure to use guide pins may result in cutting the transfer case O-ring seal during installation of the transfer case causing a fluid leak.

6. Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
7. Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.

Note: Transmission fluid may creep from the transmission bore during installation.

8. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.






9. Install the transfer case (1) to the transmission.
10. Remove the guide pins (2).






Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

11. Install the transfer case to transmission bolts (1) and tighten to 50 Nm (37 lb ft).
12. Install the engine rear mount bracket. Refer to Engine Rear Mount Bracket Replacement Service and Repair.
13. Remove the jackstand from under the transaxle.
14. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement Service and Repair.
15. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement Service and Repair.
16. Install the propeller shaft. Refer to Propeller Shaft Replacement Service and Repair.
17. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
18. Fill the transmission fluid. Refer to Transmission Fluid Drain and Fill .
19. Lower the vehicle.