: | Apr 26, 2005 |
. | Disconnect the battery ground cable. |
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Raise and support the vehicle. |
. | Drain the transfer case fluid. |
. | Remove the transfer case. |
. | With assistance, secure the transfer case with
its transmission mating face down on a flat surface.
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Remove the shift motor.
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Remove 17 Torx bolts securing the transfer casings.
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. | With assistance, release the transfer case and secure with the rear face of the transfer case facing down on a flat surface. |
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Remove the front half of the transfer case.
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Remove the 2 special washers. ![]() |
. | Remove the input shaft and oil pump assembly.
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. | Remove the front output flange.
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Remove the output flange seal. ![]() |
. | Remove the output flange bearing. ![]() |
. | Remove the sealant from the transfer case mating faces. |
. | Clean the magnetic filter. |
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Using the special tool, install the output flange bearing.
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. | Using the special tool, install a new oil seal.
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Using the special tool and with assistance, install the drive flange.
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Install the 2 special washers.
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Install the input shaft and oil pump assembly.
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. | Apply a 2 mm bead of sealant to one surface of
the transfer case mating face, as shown.
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. | Install the front half of the transfer case.
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. | With assistance, release the transfer case and secure with its transmission mating face down on a flat surface. |
. | Tighten the remaining Torx bolts to 35 Nm (26 lb.ft). |
. | Install the shift motor.
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. | With assistance, release the transfer case.
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. | Install the transfer case. |
. | Refill the transfer case with the recommended
fluid. |
. | Connect the battery ground cable. |