Transfer Case Assembly Replacement

Transfer Case Assembly Replacement

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 the catalytic converter. For the LFW engine, refer to Catalytic Converter Replacement - Right Side (LFW) (Catalytic Converter Replacement - Right Side) and for the LAF engine refer to Catalytic Converter Replacement (LAF) (Catalytic Converter Replacement - Left Side).




6. Remove the transfer case brace (3). Refer to Transfer Case Brace Replacement (LFW Engine) (Service and Repair)Transfer Case Brace Replacement (LAF Engine) (Service and Repair).
7. Remove the transfer case mounting bracket (3).
8. Support the transaxle with a jackstand.
9. Remove the rear transmission mount and bracket. Refer to Transmission Rear Mount Bracket Replacement (AWD) (Transmission Rear Mount Bracket Replacement)Transmission Rear Mount Bracket Replacement (FWD) (Transmission Rear Mount Bracket Replacement).




10. Remove the bolts (1) securing the transfer case to the transaxle.
11. Remove the transfer case (2) from the transaxle.
12. Remove the transfer case to transmission O-ring for (LFW) engine or the gasket for (LAF) engine.




13. If replacing the transfer case, complete the following steps, if applicable.

* 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, if applicable.

* Install the transfer case heat shield (2).
* Install the transfer case heat shield bolts (1) and tighten to 11 Nm (97 lb in).
* Install a NEW the transfer case to transmission O-ring for LFW engine or NEW gasket for LAF engine. Lube the O-ring with light coating of automatic transmission fluid.




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





Note: Tighten bolts in specified sequential order.

6. Install the transfer case brace (3). Refer to Transfer Case Brace Replacement (LFW Engine) (Service and Repair)Transfer Case Brace Replacement (LAF Engine) (Service and Repair).
7. Install the catalytic converter. For the LFW engine, refer to Catalytic Converter Replacement - Right Side (LFW) (Catalytic Converter Replacement - Right Side) and for the LAF engine refer to Catalytic Converter Replacement (LAF) (Catalytic Converter Replacement - Left Side).
8. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement (Front Wheel Drive Shaft Replacement).
9. Install the propeller shaft. Refer to Propeller Shaft Replacement (Service and Repair).
10. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement (Transfer Case Fluid Replacement).
11. Lower the vehicle.