A. Inspect Transfer Case

1. Raise the vehicle in a lift or hoist.

2. Inspect the transfer case for evidence of oil leakage in the areas indicated. If there is NO LEAKAGE, change the transfer case oil and return the vehicle to the customer as instructed in Step 3, below.





If there is visible oil leakage, go to Step 4 for transfer case inspection. Inspect the visible leaks thoroughly and record information concerning the leaks on the Transfer Case Leakage Dealer Check Form, which is at the end of this bulletin. Make a copy of this form. Keep this form for your records if you are re-sealing the transfer case. Send in a copy of this form with the old transfer case if you are replacing the transfer case because of damage, wear, or binding.

3. DRAIN AND REFILL THE TRANSFER CASE





a. Remove the transfer case breather.





b. Remove the transfer case filler plug

c. Remove the transfer case drain plug and drain the oil. Measure the quantity of oil removed and record it for your records on the repair order.

d. Clean and reinstall the drain plug. Tighten to the standard torque value: 300 in-lbs (35 Nm)

e. Using genuine Mitsubishi Diamond Gear Lube 75W-90/GL-5 (A991ZC2X01), refill the transfer case with the quantity indicated below:

5-speed M/T = 8.5 oz. (250cc)
6-speed M/T = 18.5 oz. (550cc)

NOTE:
A small amount of oil will remain in the transfer case after draining, therefore, use the exact quantities listed above when refilling the transfer case.

CAUTION
DO NOT overfill the transfer case. Make sure the transfer case is filled to the correct quantity as shown above. Overfilling the transfer case can cause powertrain damage.

f. Clean and reinstall the filler plug. Tighten to the standard torque value: 300 in-lbs (35 Nm)

g. Clean the transfer case breather and seat. Apply Mitsubishi Weatherstrip Adhesive (A990ZC1X03) around the breather hole and install the breather.

h. Lower the vehicle from the lift/hoist.

i. Test drive the vehicle and inspect for leakage.

j. Return the vehicle to the customer. No further action is required.

TRANSFER CASE REMOVAL

4. Inspect the transfer case for signs of any cracks or breaks. If cracks or breaks are identified, remove the transfer case using Steps 5 through 13 below, then proceed with Section C. - Installing Transfer Case.

NOTE:
Transfer case replacement requires approval from Tech Line. Be sure to contact Tech Line before ordering a new transfer case.

5. Remove the transfer case filler plug.

6. Remove the transfer case drain plug and drain the fluid from the transfer case. See illustration in Step 2-c. Measure the amount of oil which drains from the transfer case and record it on the Transfer Case Leak Dealer Check Form.





7. Remove the two nuts that secure the exhaust pipe to the rear turbocharger-mounted catalytic converter. Discard the nuts.

8. Remove the two nuts that secure the front catalytic converter to the front turbocharger outlet. Discard the nuts.

9. Disconnect the front exhaust pipe support. Disconnect the front exhaust pipe and temporarily support the front exhaust pipe with a wire or bunjee cord.

10. Remove and discard the 2 exhaust gaskets.





11. Remove the 5 bolts that secure the transfer case to the transaxle.

NOTE:
The upper mounting bolt may be hidden from view

12. Separate the transfer case from the transaxle. It may be necessary to tap the transfer case with a plastic hammer to loosen it.

13. Tilt the transfer case downward then remove the transfer case from the transaxle. Disconnect the transfer case from the driveshaft and set it on a clean work surface.

CAUTION
DO NOT let the driveshaft hang. The universal joint can be damaged of the driveshaft could bend. Support the driveshaft with a wire or bunjee cord.

TRANSFER CASE INSPECTION

14. Remove and discard the aluminum gaskets from the transfer case filler and drain plugs. Clean the filler and drain plugs. Set them aside for use later.





15. Remove the transfer case breather. Clean the breather and set it aside for re-use later.





16. Remove the bolts that secure the transfer case gear housing to the adapter housing.

NOTE:
There are five (5) bolts on 5-speed equipped vehicles and seven (7) bolts on 6-speed equipped vehicles.





17. Position the transfer case vertically on a soft pad and separate the gear housing from the adapter housing by tapping the gear housing with a plastic hammer.





CAUTION
DO NOT bend or damage the oil guide pipe when separating the housings on 6-speed equipped vehicles.





18. While holding the gear housing, rotate the input gear while inspecting for binding or chipped gear teeth.





19. While holding the adapter housing, rotate the output gear, inspecting for binding or chipped gear teeth.

20. If either the input gear or output gear do not rotate smoothly or appear to be damaged, you must replace the transfer case with a new assembly. Proceed with Section C. - Installing Transfer Case. Reassemble the original transfer case and hold for possible warranty parts return (30 days past paid, end-of-month statement date).

Transfer case replacement requires prior approval from Tech Line. Refer to the PARTS INFORMATION section of this bulletin for details regarding ordering a new transfer case.

If the input gear and output gear rotate smoothly and have no apparent damage, proceed with Section B. - Re-sealing the Transfer Case.