Transfer Unit Replacement

REMOVAL





1. Raise vehicle and drain transfer oil
Oil grade: API GL-4 or GL-5
Viscosity: SAE 75W-90
Capacity: 1.7 liters (1.8 US quarts)
Torque: 37 Nm (27 ft. lbs.).
2. Remove front and rear propeller shafts.





3. Disconnect transfer shift lever link. Remove the clip, washer, wave washer and bush, and disconnect the transfer shift lever link.





4. Disconnect ground cable. Remove the bolt and disconnect the ground cable from the transfer.
5. Remove crossmember, as follows:





a. Support the transmission, as shown.

NOTICE: Use a wooden block so not to damage the transmission oil pan.

b. Remove the eight bolts, two nuts and crossmember.
Torque:
Bolt: 61 Nm (45 ft. lbs).
Nut: 74 Nm (54 ft. lbs.).





6. Disconnect breather hose.
From the hose end to the clip end: 5 mm (0.20 inch) or more.
7. Disconnect No.1 vehicle speed sensor, center differential lock indicator switch, neutral position switch, L4 position switch and motor actuator connectors.
8. Jack up transfer slightly. Using a transmission jack, support the transfer.
9. Remove transfer from transmission, as follows:
a. Disconnect the wire harness from the transfer.





b. Remove the six transfer adaptor rear mounting bolts.
Torque: 69 Nm (51 ft. lbs.).
c. Pull out the transfer down and toward the rear.

NOTE: Take care not to damage the transfer adaptor oil seal with the transfer input gear spline.

INSTALLATION
Installation is in the reverse order of removal.

NOTE:
^ Apply Multi-Purpose (MP) grease to the transfer adaptor oil seal.
^ After installation do the road test.