Disassembly and Reassembly

Disassembly
1. Remove the drain plug from the transfer case and drain the oil.
2. Remove the speedometer sensor and driven gear.
3. Remove the front and rear speed sensor of the harness assembly from the transfer cover assembly.

Note: Use care to prevent damage to speed sensor when removing speed sensor.





4. Disconnect the clutch solenoid coil, 4H and 4L switch harness connector.
- Remove the harness bracket from the transfer cover.





5. Remove the connector bracket from the transfer case.
- Remove the harness assembly and shift motor harness connector from the connector bracket.

6. Remove the 4H and 4L switch from the transfer case.
7. Remove the shift motor assembly from the transfer cover.





8. Using the flange holder J-8614-11, remove the end nut.
Remove the washers, oil seals, front and rear companion flange.
9. Remove the transfer cover retaining bolts and the transfer cover assembly from the transfer case assembly.

Note: When removing the transfer cover assembly, use care to prevent damage to oil seal.

10. Remove the breather hose from the transfer case.

Reassembly





1. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) uniformly to the transfer case and cover fitting surface.








2. Install the plate, bracket, connector bracket and ground cable of the harness assembly, and tighten the transfer cover retaining bolts (16 pieces) to specified torque.
Torque: 31 Nm (23 ft. lbs.)
3. Install the front and rear companion flange.
4. Install the oil seal and washer, and using the flange holder J-8614-11, install the new end nut to the specified torque.
Torque: 167 Nm (123 ft. lbs.)








5. Securely stake the end nut at one spot.

Note: Be sure to confirm that there is no clack at the staked portion of the end nut after staking.





6. Apply recommended liquid gasket (LOCTITE 598 or its equivalent) to the transfer cover and shift motor assembly fitting surface.
7. Install the shift motor assembly to the transfer cover assembly.
Torque: 10 Nm (87 inch lbs.)
8. Install the 4H and 4L switch.
Torque: 24 Nm (17 ft. lbs.)
9. Install the harness assembly and shift motor harness connector to the connector bracket.
10. Install the front and rear speed sensors to the transfer cover.
Torque: 5 Nm (43 inch lbs.)





11. Connect the harness assembly connector to the clutch solenoid coil harness connector and 4H and 4L switch.
- Fix the harness with harness bracket.





12. Install the driven gear and speedometer sensor to the transfer case.
Torque: 25 Nm (19 ft. lbs.)
13. Remove the filler plug and fill the transfer case with ATF DEXRON-II or III.





14. Wind the sealing tape around the filler plug thread and tighten the plug to the specified torque.
Torque: 25 Nm (19 ft. lbs.)
15. Install the breather hose to the transfer case.