Fluid - Transfer Case: Service and Repair

Transfer Oil Replacement

1. Transfer oil is not replaced in normal condition.But it should be replaced every 75,000 miles in severe driving conditions.

NOTE:
Severe driving conditions
1. Driving in dusty, rough roads
2. Driving in mountains areas
3. Driving for patrol car, taxi, commercial car or vehicle towing
4. Driving over 170Km/h

CAUTION:
Transfer case oil should be replaced if the transfer assembly has been submerged in water.

Removal

1. Disconnect the (-) terminal from the battery.
2. Lift up the vehicle.
3. Remove the front muffler.
4. Remove the propeller shaft bolts(A-4ea).

Tightening torque :
49.0 - 68.6N.m (5.0 - 7.0kgf.m, 36.2 - 50.6lb-ft)




5. Remove the right driveshaft (passenger side) from the transfer case.

CAUTION:
Install the propeller shaft to be near runout marking (Transfer assembly 1ea, propeller shaft 1ea) each other.

6. Remove up and down mounting bolt (A, B) after removing the transfer case bracket mounting bolt (C).

[Gasoline 2.4]





[Gasoline 3.5]








7. Remove the transfer case with pry-bar after supporting the transfer case with a jack.

Installation

1. Installation is the reverse of removal.

NOTE:
- Be careful not to damage the O-ring (A). If the O-ring take damage, replace new one.
- Smear involute splines (B) all covering with molybdenum type high pressure grease.
TECHLUBE MEGAMAX - ALPHA OR EQUIVALENT