Transfer Case: Service and Repair

1. Disconnect battery ground cable.
2. Raise and support vehicle.
3. Drain oil from transfer case and transaxle.
4. Remove front exhaust pipe.
5. Scribe match marks on flanges and separate driveshaft from transfer case.
6. Remove transaxle support rod from transfer case.
7. Remove transfer control actuator.
8. Remove right hand driveshaft.
9. Remove transfer case speedometer pinion gear and gussets.
10. Place suitable jacks under transaxle and transfer case, then remove transfer case attaching bolts and lower transfer case.
11. Reverse procedure to install, noting the following:
a. Lubricate seal lips of transfer side oil seal in transaxle and driveshaft oil seal and adapter oil seal of transfer case with suitable lubricant before installing transfer case and driveshaft.
b. Apply suitable sealant on transfer case
c. Be careful not to damage transaxle oil seal when inserting spline portion of transfer case ring gear into transaxle.
d. Be careful not to damage driveshaft oil seal and adapter oil seal of transfer case when installing driveshaft.