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. Drain the transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill for the 6T30/6T40/6T45 or Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill for the 6T70/6T75.

4. Remove the propeller shaft. Refer to Propeller Shaft Replacement Removal and Replacement.

5. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

6. Remove the catalytic converter. For the LFW engine, refer to Catalytic Converter Replacement - Right Side (LFX) and for the LAF engine refer to Catalytic Converter Replacement (LEA) Catalytic Converter Replacement.




7. Remove the transfer case brace (3). Refer to Transfer Case Brace Replacement (LFW Engine) Service and Repair.

8. Remove the transfer case mounting bracket (3).

9. Support the transaxle with a jackstand.

10. Remove the rear transmission mount and bracket. Refer to Transmission Rear Mount Bracket Replacement (AWD) Transmission Rear Mount Bracket ReplacementTransmission Rear Mount Bracket Replacement (FWD) Transmission Rear Mount Bracket Replacement.




11. Remove the bolts (1) securing the transfer case to the transaxle.

12. Remove the transfer case (2) from the transaxle.

13. Remove the transfer case to transmission O-ring for (LFW) engine or the gasket for (LAF) engine.

Installation Procedure

1. Install a NEW the transfer case to transmission O-ring for LFW engine or NEW gasket for LAF engine. Lube the O-ring with light coating of automatic transmission fluid.





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.

2. Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.

3. Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.

4. 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.

5. 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.

6. 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.

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




8. Install the transfer case (2) to the transaxle.

9. Remove the guide pins.

Caution: Refer to Fastener Caution Fastener Caution.

10. Install the bolts (1) securing the transfer case to the transaxle and tighten the bolts to 50 Nm (37 lb ft).

11. Install the rear transmission mount and bracket. Refer to Transmission Rear Mount Bracket Replacement (AWD) Transmission Rear Mount Bracket ReplacementTransmission Rear Mount Bracket Replacement (FWD) Transmission Rear Mount Bracket Replacement.

12. Remove the jackstand supporting the transaxle.





Note: Tighten bolts in specified sequential order.

13. Install the transfer case brace (3). Refer to Transfer Case Brace Replacement (LFW Engine) Service and Repair.

14. Install the catalytic converter. For the LFW engine, refer to Catalytic Converter Replacement - Right Side (LFX) and for the LAF engine refer to Catalytic Converter Replacement (LEA) Catalytic Converter Replacement.

15. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement Front Wheel Drive Shaft Replacement.

16. Install the propeller shaft. Refer to Propeller Shaft Replacement Removal and Replacement.

17. Fill the transmission fluid. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill for the 6T30/6T40/6T45 or Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill for the 6T70/6T75.

18. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.

19. Lower the vehicle.