C. Installing Transfer Case

NOTE:
If you are installing a NEW transfer case, tighten the drain plug and filler plug to 300 in-lbs (35 Nm).





1. FOR 5-SPEED EQUIPPED VEHICLES:
Transfer the extension housing support bracket from the old transfer case to the new transfer case.

2. Coat the output shaft seal with a small amount of 75W-90/GL-5 gear lube.





3. Fill the transfer case through the output shaft opening with Mitsubishi 75W-90/GL-5 Diamond Gear Lube (A991ZC2X01).

NOTE:
Transfer Case Gear Lube quantities:

5-speed transfer cases require 9.25 oz (270cc)
6-speed transfer cases require 20.25 oz. (6OOcc)

CAUTION
Be sure to use the correct amount of gear lube in each transfer case. Overfilling the transfer case can cause extensive powertrain damage.

4. Coat the transfer case input shaft and output shaft splines with Mitsubishi White Lithium Grease (A999ZC1X05).

5. Apply Mitsubishi White Lithium Grease to the transaxle output shaft and the driveshaft splines.





6. Insert the driveshaft into the transfer case and then mount the transfer case onto the transaxle.

7. Install the transfer case mounting bolts and tighten the mounting bolts to 65 ft-lbs (87 Nm). Remove the temporary driveshaft support.





8. Using new exhaust gaskets and nuts, reconnect the front exhaust pipe to the front turbocharger outlet and the rear catalytic converter (Figure 26). Tighten the exhaust nuts to 37 ft-lbs (50 Nm).

9. Connect the front exhaust pipe support.

10. The repair is now completed. Lower the vehicle, test drive to make sure the powertrain operates properly and that there are no leaks. Return the vehicle to the customer when you have verified the repair is completed satisfactorily.