Removal and Replacement
Transfer Case Replacement (MH4)
Removal Procedure
1. Remove the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.
2. Drain the oil from the transmission. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.
3. Remove the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side.
4. Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement (FWD) Transmission Rear Mount Replacement (FWD)Transmission Rear Mount Replacement (AWD) Transmission Rear Mount Replacement (AWD).
5. Remove the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (Front) Catalytic Converter Replacement - Left Side (Front) and Catalytic Converter Replacement - Right Side (Rear) Catalytic Converter Replacement - Right Side (Rear).
6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).
7. Remove the transfer case bracket-to-transfer case bolts (2, 4).
8. Remove the transfer case bracket-to-engine bolts (3, 8).
9. Remove the brackets (1, 5).
10. Support the transfer case (6) with a suitable jack, and secure with suitable straps.
11. Remove the remaining transfer case-to-transmission bolts (2).
12. Separate the transfer case (1) from the transmission and remove the transfer case.
13. Remove and discard the transfer case-to-transmission O-ring.
Installation Procedure
1. Clean the contact surfaces between the transfer case and the transmission.
2. Install a new transfer case-to-transmission O-ring (1).
3. Support the transfer case with a suitable jack, and secure with suitable straps.
4. Raise and align the transfer case in the correct position in relation to the transmission.
5. Install the transfer case (1) to the transmission.
Caution: Refer to Fastener Caution Fastener Caution.
6. Install the transfer case-to-transmission bolts (2) and tighten to 110 Nm (81 lb ft).
7. Install the brackets (1, 5).
8. Install the transfer case bracket-to-transfer case bolts (2, 4)
9. Install the transfer case bracket-to-engine bolts (3, 6)
10. Tighten the bracket-to-transfer case bolts (2, 4) to 5 Nm (44 lb in).
11. Tighten the bracket-to-engine bolts (3, 6) to 22 Nm (16 lb ft).
12. Tighten the bracket-to-transfer case bolts (2, 4) to 58 Nm (42 lb ft).
13. Install the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement (FWD) Transmission Rear Mount Replacement (FWD)Transmission Rear Mount Replacement (AWD) Transmission Rear Mount Replacement (AWD).
14. Install the transfer case vent hose (2), strap (1), and bolt (3).
15. Tighten the transfer case vent hose bolt, to 22 Nm (17 lb ft).
16. Install the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (Front) Catalytic Converter Replacement - Left Side (Front) and Catalytic Converter Replacement - Right Side (Rear) Catalytic Converter Replacement - Right Side (Rear).
17. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side Front Wheel Drive Shaft Replacement - Right Side.
18. Install the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.
19. Fill the transmission with oil. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.
20. Fill with transfer case oil. Refer to Approximate Fluid Capacities [1][2]Capacity Specifications.