: | Apr 28, 2005 |
. | Disconnect the battery ground cable. |
. |
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.
|
. |
Remove the shift motor.
![]() |
. |
Remove 17 Torx bolts securing the transfer casings.
![]() |
. |
Remove the rear half of the transfer case.
![]() |
. | Remove the differential module.
![]() |
. |
:
Remove the clutch, chain and sprocket. ![]() |
. | Remove the rear output flange.
![]() |
. |
Remove the output flange seal. ![]() |
. | Remove the output flange bearing.
![]() |
. | Release the front half of the transfer case from
the flat surface.
|
. | Remove the sealant from the transfer case mating faces. |
. | Clean the magnetic filter. |
. |
Using the special tool, install the output flange bearing.
![]() |
. | Using the special tool, install a new oil seal.
![]() |
. |
Using the special tool and with assistance, install the drive flange.
![]() |
. | Secure the rear half of the transfer case with its rear face down on a flat surface. |
. |
:
Install the differential module.
![]() |
. |
:
:
Install the clutch.
![]() |
. |
:
Install the chain and sprocket.
![]() |
. | Apply a 2 mm bead of sealant to one surface of
the transfer case mating face, as shown.
![]() |
. | Install the front half of the transfer case.
![]() |
. | Tighten the remaining Torx bolts to 35 Nm (26 lb.ft). |
. | Install the shift motor.
|
. | With assistance, release the transfer case from
the flat surface.
|
. | Install the transfer case. |
. | Refill the transfer case with the recommended
fluid. |
. | Connect the battery ground cable. |