Transfer Case
Transfer Case - All Wheel Drive (AWD)Special Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Disassembly
1. CAUTION: Discard all seals after removing them.
Remove the transfer case from the vehicle.
2. WARNING: Make sure the holding fixture lockpin is secure.
Using the special tool, secure the transfer case to a bench.
3. If not done previously, remove the drain plug and drain the fluid.
^ Install the drain plug when finished draining.
4. NOTE: Index-mark the rear output flange and the upper output shaft.
Using the special tool to hold the output flange, remove the output flange nut.
5. Remove the output flange and the output shaft yoke washer.
6. Remove the oil seal.
7. Remove the 17 transfer case bolts.
8. Using a pry bar, separate the rear case from the front case.
^ Pry only at the transfer case pry bosses.
9. Remove the oil seal.
10. Remove the bearing.
11. Expand the snap ring, then remove the output shaft and bearing.
12. Using the special tools, remove the bearing.
13. Remove the snap ring.
14. Using a suitable press, remove the bearing.
15. Remove the damper snubber.
16. Remove the upper planetary gear, the thrust washer, the planetary, the upper drive sprocket, the drive chain, the lower drive sprocket and the sprocket spacer as an assembly.
17. Remove the input shaft.
18. Remove the input shaft bearing.
19. Holding the front output shaft, remove the snap ring and the front output shaft.
20. Using the special tools, remove the bearings.
21. Remove the seals.
Assembly
1. Using the special tool, install the seals in the front transfer case.
2. Using the special tools, install the bearing.
3. Install the front output shaft.
^ Install the front output shaft.
^ Install the snap ring.
4. Install the damper snubbers.
^ Tighten the Torx(R) screws to 7 Nm (62 inch lbs.)
5. Using the special tools, install the bearing.
6. Install the input shaft.
7. Assemble the upper drive sprocket, lower drive sprocket and the drive chain.
8. Install the upper and lower drive sprockets and the drive chain as an assembly.
9. Install the lower planetary gear.
10. Install the front planetary gear assembly.
11. Install the thrust washer.
12. Install the upper planetary gear.
13. Install the spacer.
14. Using the special tool, install the bearing.
15. Install the output shaft and bearing in the rear case half.
^ Expand the snap ring. Install the output shaft.
16. Using the special tool, install the yoke-to-flange seal.
17. CAUTION: Applying excess silicone rubber can damage the internal components.
Apply a 3 mm (0.125 inch) bead of silicone rubber on the rear case mating surface.
18. Assemble the front and rear case halves.
19. Install the transfer case bolts.
^ Tighten to 25 Nm (18 ft. lbs.) evenly in a star pattern.
20. Using the special tool to hold the output flange, install the nut.
^ Tighten to 355 Nm (262 ft. lbs.)
21. Install the transfer case in the vehicle.
22. Fill the transfer case.