Removal and Installation

(1) Rear propeller shaft
(2) Front propeller shaft
(3) Transfer case assembly

Transfer Case Assembly

Removal

NOTE: Before removing transmission and transfer assembly from vehicle, change the transfer mode to 2WD using the 4WD rotary switch on dash panel.

1. Disconnect battery ground cable.
2. Raise and support vehicle with suitable stands. Drain transfer case fluid.
3. Remove rear propeller shaft (1) and front propeller shaft (2).

NOTE: Apply alignment marks on the flange at both front and rear sides.

4. Disconnect harness connectors and clip.
Connector: transfer switch, 2WD-4WD actuator, speed sensor.

NOTE: Avoid turning the vehicle ignition switch to the ON position when the 2WD-4WD connector is removed (battery connected).

If the ignition switch must be turned to the ON position, the controller must first be removed (memory must be cleared because the CHECK 4WD INDICATOR will light).

5. Support transmission case with a transmission jack.
6. Remove the top position bolt from transfer control lever hole and others under the floor.
Remove transfer case (3) from the vehicle.

Installation





1. Apply a thin coat of molybdenum disulfide grease to the input shaft spline as shown in the figure.

For M/T:

For A/T:

2. Install the transfer case (3) to the transmission. Tighten the transfer bolts as shown.
3. Remove the transmission jack from transmission side.
4. Connect harness connectors and clip.
Connector: transfer switch, 2WD-4WD actuator, speed sensor.
5. Install rear propeller shaft (1) and front propeller shaft (2).

Torque 63 Nm (46 ft.lb.)