Transfer Case Removal

TRANSFER CASE

COMPONENTS:

REMOVAL

[2.0L]
1. Remove the battery (-) terminal.
2. Lift up the vehicle.
3. Remove the propeller shaft.





4. Remove the front muffler (A).
5. Remove the RH driveshaft.
6. Loosen the oil drain plug and drain the fluid.
7. After draining, re-tighten the oil drain plug.
TORQUE: 39.2 - 58.8 Nm (400 - 600 kgf-cm, 28.9 - 43.4 ft. lbs.)
8. Support the transfer assembly with a jack.
9. Remove the transfer assembly by loosening the mounting bolts.

CAUTION: Remove the transfer bracket mounting bolts (2EA) together.

[2.7L 4WD)

NOTE:
1. The repair of the transfer assembly requires a special skill and furthermore an improper adjustment of the spacers may cause a severe noise and durability issue.
2. Hypoid gear set is manufactured and controlled as a pair. Any replacement of the part is to be done as a pair, hypoid gear shaft assembly 47308-39200 and pinion shaft 47311-39000.

1. Remove the battery negative (-) cable.





2. Remove the air intake hose and air cleaner cover and then disconnect the oxygen sensor connector. (A-Engine room left side).





3. Disconnect the oxygen sensor connector (B) and remove the oxygen sensor connector wire clamp from a bracket. (Engine room right side).
4. Remove the wheel and tire (RH).





5. Remove the engine side cover (A) (RH).
6. Lift up the vehicle.





7. Remove the lower arm ball joint mounting bolts (A).
8. Remove the lower arm ball joint from the front axle knuckle.





9. Remove the steering bar tie rod ball joint (A) from the knuckle.





10. Remove the drive shaft (A) from the transfer.





11. Remove the front exhaust pipe (A).
12. Drain the transfer oil through drain plug hole.





13. Remove the pinion case mounting bolts (A).





14. Remove the alternator drive belt (A) using the tensioner and then alternator assembly (C) by loosening the mounting bolts (B).





15. Remove the alternator wire terminal mounting nut (A) and connector (B).





16. Remove the heat protector (A) using a hexagonal socket.

NOTE: To remove the heat protector mounting bolt easily, before removing the heat protector mounting bolts (3EA), apply the mounting bolt with WD-40 stops squeaks.

17. Lift up the vehicle.
18. Remove the exhaust manifold mounting nuts (7EA).

NOTE: To remove the exhaust manifold mounting nut easily, before removing the exhaust manifold mounting nuts (7EA), apply the mounting nuts with WD-40 stops squeaks.





19. Remove the transfer mounting bracket (A).
20. Remove the transfer mounting bolts (4EA).
21. Using a flat head screw driver, remove the transfer from the transaxle by moving the driver to left and right directions.