Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

Removal Procedure

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




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




10. Remove the half shaft retainer (1).
11. Remove the shaft O-ring seal (2).
12. Remove the transfer case O-ring seal (3), then discard the O-ring.

Installation Procedure




1. Lubricate the O-rings (2, 3) with petroleum jelly.
2. Install the shaft O-ring seal (2).
3. Install the half shaft retainer (1).
4. Install the NEW transfer case O-ring seal (3).





Note: Oxidation must be removed from the transmission torque converter housing differential bore surface 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.

5. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
6. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
7. 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.

8. 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.
9. 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.

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




11. Install the transfer case (1) to the transmission.
12. Remove the guide pins (2).





Caution: Refer to Fastener Caution (Fastener Caution).

13. Install the transfer case to transmission bolts (1).

Tighten the bolts to 50 Nm (37 lb ft).

14. Install the engine rear mount bracket. Refer to Engine Rear Mount Replacement (Engine Rear Mount Replacement).
15. Remove the jackstand from under the transaxle.
16. Install the exhaust flexible pipe. Refer to Exhaust Flexible Pipe Replacement (Service and Repair).
17. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (Service and Repair).
18. Install the propeller shaft. Refer to Propeller Shaft Replacement (Service and Repair).
19. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
20. Lower the vehicle.