:	Apr 27, 2005

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Disconnect the battery ground cable.

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: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands. Raise and support the vehicle.

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Drain the transfer case fluid.

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Remove the transfer case.

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With assistance, secure the transfer case with its transmission mating face down on a flat surface.   Secure with 2 bolts.

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: Eye protection must be worn. Remove the shift motor.   Remove the 4 bolts.   Remove any debris from the bolt holes.

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: Eye protection must be worn. Remove 17 Torx bolts securing the transfer casings.   The two bolts indicated remain fully tightened.   Remove any debris from the bolt holes.

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: Eye protection must be worn.   : Care must be taken to avoid damage to the mating surfaces. Remove the rear half of the transfer case.   Remove the remaining 2 Torx bolts.   Remove any debris from the bolt holes.   Use a soft faced mallet.

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Remove the differential module.   Remove the spacer.

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:   Remove as an assembly. Remove the clutch, chain and sprocket.

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Remove the rear output flange.   Compress the snap ring.   Press the flange through the bearing.   Remove and discard the snap ring.

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: Care must be taken to avoid damage to the seal register and running surface. Remove the output flange seal.

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Remove the output flange bearing.   Remove the circlip.

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Release the front half of the transfer case from the flat surface.   Remove the 2 bolts.

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Remove the sealant from the transfer case mating faces.

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Clean the magnetic filter.

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: The chamfer on the bearing inner track must face the seal. Using the special tool, install the output flange bearing.   Clean the components mating faces.   Install the circlip.

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Using the special tool, install a new oil seal.   Clean the component mating faces.   Grease the new seal.

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: Centralise the snap ring in the snap ring groove before installing the output flange.   : Extreme care is necessary to make sure the snap ring enters the bearing squarely. Using the special tool and with assistance, install the drive flange.   Clean the component mating faces.   Install a new snap ring.   Make sure the snap ring is fully engaged and retains the drive flange.

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Secure the rear half of the transfer case with its rear face down on a flat surface.

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:   Rotate the differential to engage the splines. Install the differential module.   Clean the components.   Install the spacer.

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:   Rotate the assembly to engage the clutch plates. :   Use circlip pliers to open the actuator levers. Install the clutch.   Clean the components.   Engage the actuator levers.

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: The dark links in the chain face up as shown. :   The relieved splined inner diameter of the sprocket must face up as shown. Install the chain and sprocket.   Clean the components.

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Apply a 2 mm bead of sealant to one surface of the transfer case mating face, as shown.   Clean the component mating faces.   Clean the dowels and dowel holes.

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Install the front half of the transfer case.   Evenly tighten the 2 Torx bolts shown to 35 Nm (26 lb.ft).

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Tighten the remaining Torx bolts to 35 Nm (26 lb.ft).

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Install the shift motor.   Clean the components.   Tighten the Torx bolts to 25 Nm (18 lb.ft).

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With assistance, release the transfer case from the flat surface.   Remove the 2 bolts.

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Install the transfer case.

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Refill the transfer case with the recommended fluid.

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Connect the battery ground cable.