Transfer Case Assembly Replacement

Transfer Case Assembly Replacement (LZ4) (3.5L)

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
3. Remove the propeller shaft. Refer to Propeller Shaft Replacement (Service and Repair).
4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).
5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side) and Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).




6. Remove the transfer case mounting bracket bolts (1).
7. Remove the transfer case mounting bracket (2).




8. Remove the transfer case mounting bracket bolts (1, 3) and stud (2).
9. Remove the transfer case mounting bracket (4).
10. Support the transaxle with a jackstand.
11. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear (FWD) (Transmission Mount Bracket Replacement - Rear)Transmission Mount Bracket Replacement - Rear (AWD with LZ4) (Transmission Mount Bracket Replacement - Rear)Transmission Mount Bracket Replacement - Rear (AWD with LY7) (Transmission Mount Bracket Replacement - Rear).




12. Remove the bolts (1) securing the transfer case to the transaxle.
13. Remove the transfer case (2) from the transaxle.




14. If replacing the transfer case, complete the following steps.

* Remove the transfer case heat shield bolts (1).
* Remove the transfer case heat shield (2).

Installation Procedure





Caution: Refer to Fastener Caution (Fastener Caution).

1. If the transfer case heat shield was previously removed, complete the following steps.

* Install the transfer case heat shield (2).
* Install the transfer case heat shield bolts (1) and tighten to 10 Nm (89 lb in).




2. Install the transfer case (2) from the transaxle.
3. Install the bolts (1) securing the transfer case to the transaxle. Tighten the bolts to 50 Nm (37 lb ft).
4. Install the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear (FWD) (Transmission Mount Bracket Replacement - Rear)Transmission Mount Bracket Replacement - Rear (AWD with LZ4) (Transmission Mount Bracket Replacement - Rear)Transmission Mount Bracket Replacement - Rear (AWD with LY7) (Transmission Mount Bracket Replacement - Rear).
5. Remove the jackstand supporting the transaxle.





Note: Tighten the bolts in the specified sequential order.

6. Install the transfer case mounting bracket (4).
7. Install the transfer case mounting bracket bolts (1) and stud (2) and tighten the bolts/studs in specified sequential order to 50 Nm (37 lb ft).
8. Install the transfer case mounting bracket bolt (3) and tighten to 23 Nm (17 lb ft).




9. Install the transfer case mounting bracket (2).
10. Install the transfer case mounting bracket bolts (1) and tighten to 50 Nm (37 lb ft).
11. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side (LZ4) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LY7) (Catalytic Converter Replacement - Right Side)Catalytic Converter Replacement - Right Side (LCS) (Catalytic Converter Replacement - Right Side) and Catalytic Converter Replacement - Left Side (LZ4) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LY7 ) (Catalytic Converter Replacement - Left Side)Catalytic Converter Replacement - Left Side (LCS) (Catalytic Converter Replacement - Left Side).
12. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).
13. Install the propeller shaft. Refer to Propeller Shaft Replacement (Service and Repair).
14. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
15. Lower the vehicle.