Transfer Case - Offset Lever, and Companion Flange

Transfer Case





Disassembled View
Disassembly
1. Remove the drain plug from the transfer case and drain the oil.
2. Disconnect the 4H and 4L switch and grounding cable.
3. Remove the clip fixing the harness.
4. Using the flange holder J-8614-11, remove the flange nut and front companion flange.





5. Using the flange holder J-8614-11, remove the flange nut and rear companion flange.





6. Remove the offset lever set bolt on the right side.
7. Remove the offset lever lock spring pin.





8. Remove the offset lever.
9. Remove the sixteen bolts and detach the transfer cover assembly from the transfer case assembly.

Notice: When removing the transfer cover assembly, be careful not to damage the oil seal.

Reassembly





1. Apply liquid gasket (Loctite 598 or equivalent) uniformly to the mating face that contacts the transfer case.
2. Tighten the sixteen bolts to the specified torque.
Torque: 31 Nm (23 ft. lbs.)
3. Wind the sealing tape around the drain plug thread and tighten the plug with the specified torque.
Torque: 25 Nm (18 ft. lbs.)
4. Install offset lever.





5. Mount the offset lever to the transfer shift rod and install the spring pin.
6. Install rear and front companion flange.
7. Attach the O-ring and washer to the companion flange.

Notice: Securely push the O-ring to the hollow of the companion flange, and then attach the washer.

8. Use the flange holder J-8614-11 to tighten the flange nuts to transfer case.
9. Tighten the flange nuts to the specified torque.
Torque: 167 Nm (123 ft. lbs.)








10. Using the punch J-39209, securely stake each flange nut at two spots.

Notice: Check the staked flange nuts are free from cracks.

11. Fix the harness with the clip.
12. Tighten the 4L and 4H switch to the specified torque.
Torque: 24 Nm (17 ft. lbs.)
13. Fill the transfer case with ATF II or III (1.9 liters).
14. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque.
Torque: 25 Nm (18 ft. lbs.)