Transfer Case Installation

TRANSFER CASE

INSTALLATION

[2.0L]





1. Remove the filler plug (A).
2. Refill the specification to the specified quantity.
Specification: SAE 80W/90
Quantity: 0.8 Liters
3. Fix it in proper position with mounting bolts.

[2.7L 4WD]
1. Install the transfer assembly to the transaxle.

NOTE: To install the transfer easily, install it by moving the pinion left and right directions, and slightly rotating the inner drive shaft of transfer assembly.
2. Install the transfer mounting bolts (4EA).
TORQUE: 60.8 - 65.7 Nm (620 - 670 kgf-cm, 44.8 - 48.5 ft. lbs.)





3. Install the transfer mounting bracket (A).
TORQUE: 46.1 - 50.0 Nm (470 - 510 kgf-cm, 34.0 - 36.9 ft. lbs.) - 2EA
23.5 - 27.5 Nm (240 - 280 kgf-cm, 17.4 - 20.3 ft. lbs.) - 3EA
4. Tighten the exhaust manifold mounting nuts (7EA).
TORQUE: 29.4 - 34.3 Nm (300 - 350 kgf-cm, 21.7 - 25.3 ft. lbs.)





5. Tighten the heat protector (A) mounting nuts (3EA).
TORQUE: 11.8 - 14.7 Nm (120 - 150 kgf-cm, 8.7 - 10.8 ft. lbs.)





6. Connect the alternator wire terminal (A) and connector (B).





7. Install the alternator drive belt (A) using the tensioner and then alternator assembly (C) by tightening the mounting bolts (B).
TORQUE: 19.6 - 29.4 Nm (200 - 300 kgf-cm, 14.5 - 21.7 ft. lbs.)
8. Tighten the pinion case mounting bolts (6EA).
TORQUE: 36.3 - 39.2 Nm (370 - 400 kgf-cm, 14.5 - 21.7 ft. lbs.)
9. Refill the transfer oil through the filler plug.





10. Install the front exhaust pipe (A).
11. Install the drive shaft (RH) to the transfer assembly, lower arm ball joint mounting and steering bar tie rod ball joint.
12. Lower the vehicle down.
13. Install the engine side cover (RH) and the wheel and tire (RH).





14. Connect the oxygen sensor connector (B) and insert the oxygen sensor connector wire clamp into a bracket. (Engine room right side).





15. Install the air intake hose and air cleaner cover and then connect the oxygen sensor connector. (A-Engine room left side).
16. Connect the battery negative (-)cable.