Transfer Case Installation
Transfer Case (46.10.01)Special Service Tools:
Installation
All vehicles
1. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
NOTE: Using a suitable solvent clean the seal face on the housing before fitting a new seal.
Using the special tool, install the link shaft oil seal.
If any transfer case fluid is lost during installation carry out drain and refill.
2. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
Install the link shaft into the transfer case.
3. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
Install a new link shaft snap ring.
4. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
Install a new O-ring seal.
5. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
Install the special tool.
6. CAUTION: Make sure there is no loss of fluid from the transfer case. Failure to follow this instruction may result in damage to the transfer case.
With the aid of an assistant install the transfer case.
Tighten to 90 Nm.
If any transfer case fluid is lost during installation carry out drain and refill.
7. Remove the special tool.
Engage the link shaft into the transfer case.
8. NOTE: Do not tighten the engine anti-roll restrictor bracket top retaining bolt at this stage.
Install the engine anti-roll restrictor bracket.
Install the engine anti-roll restrictor bracket top retaining bolt.
9. NOTE: Do not tighten the engine anti-roll restrictor bracket retaining nuts at this stage.
Install the engine anti-roll restrictor bracket retaining nuts.
10. NOTE: Do not tighten the engine anti-roll restrictor bracket retaining bolts at this stage.
Install the engine anti-roll restrictor bracket side retaining bolts.
11. NOTE: Do not tighten the catalytic converter mount bracket retaining bolts at this stage.
Install the catalytic converter mount bracket.
12. Using the special tool, tighten the catalytic converter mount bracket, top left-hand retaining bolt.
Use the calculation in step 13 to produce the correct torque to apply to the retaining bolt.
13. Using the special tool and a torque wrench, tighten the catalytic converter mount bracket, top left-hand retaining bolt.
To make sure the catalytic converter mount bracket, top left-hand retaining bolt is torqued to the correct specification the following calculation steps must be used.
Step 1. Multiply 55 Nm by the effective length of the torque wrench (1).
Step 2. Add the effective length of the special tool (2) to the effective length of the torque wrench (1).
Step 3. Divide the total of step 1 by the total of step 2.
Step 4. Set the torque wrench to the figure arrived at in step 3.
Tighten the catalytic converter mount bracket, top left-hand retaining bolt to the torque given by the calculation.
14. Tighten the catalytic converter mount bracket retaining bolts.
Tighten to 55 Nm.
15. Tighten the catalytic converter mount bracket retaining bolt.
Tighten to 55 Nm.
16. Install the catalytic converter mount bracket to transfer case retaining bolt.
Tighten to 25 Nm.
17. Tighten the engine anti-roll restrictor bracket top retaining bolt.
Tighten to 55 Nm.
18. Tighten the engine anti-roll restrictor bracket retaining nuts.
Tighten to 35 Nm.
19. Tighten the engine anti-roll restrictor bracket side retaining bolts.
Tighten to 35 Nm.
20. NOTE: Do not tighten the engine roll restrictor retaining bolt at this stage.
Install the engine roll restrictor.
Install the engine roll restrictor retaining bolt.
21. Attach the engine roll restrictor.
Tighten to 80 Nm.
22. Tighten to 80 Nm.
23. Install the catalytic converter to catalytic converter mount bracket retaining bolts.
Tighten to 25 Nm.
24. NOTE: Alternator cooling duct shown removed for clarity.
Install transfer case support bracket.
Tighten to 47 Nm.
25. Install transfer case support bracket top retaining bolts.
Tighten to 25 Nm.
26. Install a new snap ring to the halfshaft.
27. Install a new halfshaft seal.
28. CAUTION: Make sure the halfshaft constant velocity (CV) joints do not over articulate. Failure to follow this instruction may result in damage to the CV joints.
Remove the halfshaft support strap.
29. CAUTION: Make sure the CV joint splines are located fully. Do not use excessive force when engaging the CV joint into the link shaft.
Install the halfshaft.
30. NOTE: Install a new retaining nut.
Attach the wheel knuckle.
1. Reposition the lower arm.
2. Attach the wheel knuckle.
3. Install the lower arm ball joint retaining nut and bolt.
Tighten to 83 Nm.
31. Loosely install the right-hand front subframe rear mount retaining bolt.
32. NOTE: Left-hand shown, right-hand similar.
Loosely install the front subframe reinforcement plate retaining bolts.
33. NOTE: Left-hand shown, right-hand similar.
Tighten to 142 Nm.
34. NOTE: Left-hand shown, right-hand similar.
Tighten the front subframe reinforcement bolts.
M8 to 35 Nm.
M10 to 70 Nm.
35. Install the driveshaft using new driveshaft retaining bolts. Tighten bolts in a cross pattern and torque to 44 Nm.
Vehicles with manual transmission
36. Fill the manual transmission to the correct oil level.
Vehicles with automatic transmission
37. Connect the selector lever cable.
38. Attach the selector lever cable bracket.
Tighten to 10 Nm.
39. Fill the automatic transmission to the correct oil level.
40. Install the selector lever cable shield.
Tighten to 10 Nm.
All vehicles
41. Install the muffler inlet pipe.
42. Install the front pipe.
Tighten to 55 Nm.
43. Install the fender splash shield access panel.
44. Install the right-hand front wheel and tire.
45. Tighten the shock absorber and spring assembly securing nuts.
Tighten to 25 Nm.
46. NOTE: Install a new steering column lower retaining bolt.
Attach the steering column.
