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. Remove the exhaust front pipe. Refer to Front Pipe Replacement.

3. Remove the propeller shaft from the transfer case. Refer to Propeller Shaft Replacement.

4. Remove the right front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.

5. If equipped with gasoline engine, remove the rear catalytic converter. Refer to Catalytic Converter Replacement.




6. Remove the transfer case bracket bolts (1).

7. If equipped with manual transmission, remove the transmission rear mount bracket. Refer to Transmission Rear Mount Bracket Replacement.

8. If equipped with automatic transmission, remove the transmission rear mount bracket. Refer to Transmission Mount Bracket Replacement.




9. Remove lower transfer case bolts (1).

10. Support the transfer case using the supporting jack.




11. Remove the transfer case from the transaxle.

12. Remove the transfer case to transmission O-ring, then discard the O-ring.

13. Plug the transaxle to minimize the transaxle fluid loss.

Installation Procedure

Note: Transmission fluid may creep from the transmission bore during installation.

1. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.

2. Install a NEW transfer case to transmission O-ring.




3. Install the transfer case from the transaxle.





Caution: Refer to Fastener Caution Fastener Caution.

4. Install the lower transfer case bolts (1) and tighten to 75 Nm (55 lb ft)

5. If equipped with manual transmission, install the transmission rear mount bracket. Refer to Transmission Rear Mount Bracket Replacement.

6. If equipped with auto transmission, install the transmission rear mount bracket. Refer to Transmission Mount Bracket Replacement.




7. Install the transfer case bracket bolt (1) and tighten to 58 Nm (43 lb ft).

8. Install the right front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement.

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

10. If equipped with gasoline engine, install the rear catalytic converter. Refer to Catalytic Converter Replacemen.

11. Install the exhaust front pipe. Refer to Front Pipe Replacement.