Repair Procedures

SELECTOR SHAFT SEAL REPLACEMENT SRO:41.20.59

Removal

1. Place vehicle on lift and raise for access.

2. Unplug both shift control motor electrical connectors and move wiring out of the way

3. Remove two nuts and one bolt securing end bracket.

WARNING:
Do not loosen three Torx(R) screws securing encoder switch to shift control motor. The switch adjustment is set from the factory and must not be changed.

Remove three bolts securing shift control motor and remove motor.

4. Use a suitable tool to remove selector shaft seal from transfer gearbox.

CAUTION:
Take care to avoid damage to seal installation area when removing old seal.

INSTALLATION

1. Lightly oil selector shaft seal and install into transfer gearbox. Use a socket the same size as the seal (a 15 mm Snap-On(R) deep well can be used).

2. Set seal flush to flange surface do not pass the shaft flange.

3. Apply Right Stuff RTV to the mating surface of the shift control motor.

4. Install new shift control motor onto transfer gearbox with four bolts. Tighten to 10 Nm. (88 in. lb.).

5. Reconnect both electrical connectors.

6. Check transfer gearbox fluid level and replenish as necessary.

7. Check transfer gearbox vent line to ensure that it is clear.

TRANSFER GEARBOX ECU REPLACEMENT SRO: 41.30.01

(This revised procedure does not require seat removal)

REMOVAL

1. Adjust the front left hand seat all the way forward and raise to the highest level.

2. Obtain radio code and disconnect the battery negative lead.





3. Remove two screws securing rear floor heater air duct (Figure 5, Ref 1) and remove duct.

4. Raise carpet and insulation mat for access.

5. Remove two screws securing heater duct mounting (Figure 5, Ref 2). Remove mounting.

6. Remove left hand screw and loosen right hand screw securing TCU.

CAUTION:
Ensure that the white anti-backout strip remains in the TCU harness connector.

7. Remove TCU and disconnect multi-plug.

INSTALLATION

1. Connect multi-plug. Position new TCU and secure with screws.

2. Position rear floor heater duct mounting and secure with screws.

3. Position insulation mat and carpet. Ensure seat harness is not trapped.

4. Position rear floor heater air duct. Secure with screws.

5. Connect negative battery lead.

6. Position front seat to original position.

7. Code radio, set windows and sunroof.

8. Synchronize remote.





TCU Pin Layout

Note:
View is looking into TCU connector