Transfer Case: Service and Repair

REMOVAL
Preparation:
- Disconnect battery negative (-) cable.
- Drain transfer case fluid.

1. Exhaust and transfer protectors
2. Rear propeller shaft
3. Front propeller shaft
- Remove the rear and front propeller shaft from the transfer case side.
4. Exhaust pipe
- Remove the catalytic converter.
- Remove the center exhaust pipe.
- Disconnect oxygen sensor connector from the transmission harness.
5. Front console
- Remove the transfer control lever knob.
- Disconnect the harness connectors.
6. Selector lever assembly






- Disconnect the shift lock cable from the selector lever assembly side
- Disconnect the harness connectors.






- Disconnect the shift control rod from the selector lever assembly side

7. Transfer control lever
8. Wiring harness connector
- Disconnect the 4WD switch and speed sensor harness connector from the transmission harness.
9. Transmission-transfer bolt
- Support the transfer case with a transmission jack.
- Remove four transmission-transfer bolts and three nuts.
10. Transfer case assembly
- Remove the transfer case assembly from the vehicle.

INSTALLATION
To install, follow the removal steps in the reverse order, noting the following points:






1. Transfer case assembly






Note: Apply a thin coat of molybdenum disulfide grease to the input shaft spline






- Transmission/transfer bolts