Transfer Case Replacement

Transfer Case Replacement

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 (GNB) Front Wheel Drive Shaft Replacement (GNB)Front Wheel Drive Shaft Replacement (GNA) Front Wheel Drive Shaft Replacement (GNA).

4. Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement (AWD) Transmission Rear Mount ReplacementTransmission Rear Mount Replacement (FWD) Transmission Rear Mount Replacement.

5. Remove the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LFX-Front) Catalytic Converter Replacement - Left Side (LFX-Front) and Catalytic Converter Replacement - Right Side (LFX-Rear) Catalytic Converter Replacement - Right Side (LFX-Rear).




6. Remove the transfer case vent hose strap (1), bolt (3), and hose (2).




7. Remove the transfer case support bracket-to-transfer case bolts (2).

8. Remove the transfer case support bracket-to-engine bolts (3).

9. Remove the support bracket (1).

10. Support the transfer case with a suitable jack, and secure with suitable straps.




11. Remove the transfer case-to-transmission center bolt. The center bolt (3) is accessed through the opening in the center of the transfer case.




12. Remove the remaining transfer case-to-transmission bolts (2).

13. Separate the transfer case (1) from the transmission and remove the transfer case.

Installation Procedure




1. Clean the contact surfaces between the transfer case and the transmission. Install a new transfer case-to-transmission O-ring (1).




2. Support the transfer case with a suitable jack, and secure with suitable straps.

3. Raise and align the transfer case in the correct position in relation to the transmission.

4. Install the transfer case (1) to the transmission.

Caution: Refer to Fastener Caution Fastener Caution.

5. Install the transfer case-to-transmission bolts (2).




6. Install the transfer case-to-transmission center bolt. The center bolt is accessed through the opening in the center of the transfer case.

7. Tighten the bolts (3) to 110 Nm (81 lb ft).




8. Install the support bracket (1).

9. Install the transfer case support bracket-to-transfer case bolts (2).

10. Install the transfer case support bracket-to-engine bolts (3).

11. Install the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.

1. Tighten the support bracket-to-transfer case bolts (2) to 5 Nm (44 lb in).

2. Tighten the support bracket-to-engine bolts (3) to 60 Nm (44 lb ft).

3. Tighten the support bracket-to-transfer case fasteners (1) to 60 Nm (44 lb ft).

12. Install the transmission rear mount bracket.




13. Install the transfer case vent hose (2), strap (1), and bolt (3).

14. Tighten the transfer case vent hose bolt, if equipped, to 22 Nm (17 lb ft).

15. Install the front catalytic converters. Refer to Catalytic Converter Replacement - Left Side (LFX-Front) Catalytic Converter Replacement - Left Side (LFX-Front) and Catalytic Converter Replacement - Right Side (LFX-Rear) Catalytic Converter Replacement - Right Side (LFX-Rear).

16. Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement (GNB) Front Wheel Drive Shaft Replacement (GNB)Front Wheel Drive Shaft Replacement (GNA) Front Wheel Drive Shaft Replacement (GNA).

17. Install the propeller shaft. Refer to Propeller Shaft Replacement Propeller Shaft Replacement.

18. Check the fluid level in the transfer case. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.

19. Fill the transmission with oil. Refer to Transmission Fluid Drain and Fill Transmission Fluid Drain and Fill.

20. Fill the transfer case fluid. Refer to Transfer Case Fluid Replacement Transfer Case Fluid Replacement.