Transfer Case - All-Wheel Drive (AWD)
Transfer Case - All-Wheel Drive (AWD)
Disassembly
1. NOTE: Discard all seals after removing them.
Remove the transfer case from the vehicle. For additional information, refer to Transfer Case Transfer Case - Removal.
2. WARNING: Always verify that the lockpin on the bench-mounted holding fixture is correctly secured to help prevent unexpected component rotation. Failure to follow this instruction may result in serious personal injury.
Using the Transmission Holding Fixture, secure the transfer case to a bench.
3. If not done previously, remove the drain plug and drain the fluid.
- Install the drain plug when finished draining.
- Tighten to 20 Nm (177 lb-in).
4. NOTE: Index-mark the rear output flange and the upper output shaft.
Using the Drive Pinion Flange Holding Fixture to hold the output flange, remove the output flange nut.
5. Remove the output flange and the output shaft yoke washer.
6. Remove the oil seal.
7. Remove the 17 transfer case bolts.
8. NOTICE: Pry only at the transfer case pry bosses. Prying other than at the pry bosses may cause damage to the components.
Using a pry bar, separate the rear case from the front case.
9. Remove the oil seal.
10. Remove the bearing.
11. Expand the snap ring, then remove the output shaft and bearing.
12. Using the Slide Hammer and Stator Bearing Remover, remove the bearing.
13. Remove the snap ring and discard.
14. Using a suitable press, remove the bearing.
15. Remove the 4 Torx screws and the damper snubber.
16. Remove the sun gears, the thrust washer, the planetary, the upper drive sprocket, the drive chain, the lower drive sprocket and the sprocket spacer as an assembly.
17. Remove the input shaft.
18. Remove the input shaft bearing.
19. Holding the front output shaft, remove the snap ring and discard, then remove the front output shaft.
20. Using the Slide Hammer and Bearing Cup Remover, remove the bearings.
21. Remove the seals.
Assembly
1. Using the Front Pump Fluid Seal Installer, install the seals in the front transfer case.
2. Using the Differential Bearing Cup Installer and Handle with Adapter, install the bearing.
3. Install the front output shaft.
- Install the front output shaft.
- Install a new snap ring.
4. Position the damper snubber and install the 4 Torx screws.
- Tighten to 7 Nm (62 lb-in).
5. Using the Wheel Hub Bearing Cup Installer and Handle with Adapter, install the bearing.
6. Install the input shaft.
7. Assemble the upper drive sprocket, lower drive sprocket and the drive chain.
8. Install the upper and lower drive sprockets and the drive chain as an assembly.
9. Install the lower sun gear.
10. Install the front planetary gear assembly.
11. Install the thrust washer.
12. Install the upper sun gear.
13. Install the spacer.
14. Using the Bearing Tube Remover/Installer, install the bearing.
15. Install the output shaft and bearing in the rear case half.
- Expand the snap ring. Install the output shaft.
16. Using the Front Pump Fluid Seal Installer, install the yoke-to-flange seal.
17. NOTICE: Applying excess silicone rubber can damage the internal components.
Apply a 3 mm (0.125 in) bead of silicone rubber on the rear case mating surface.
18. Assemble the front and rear case halves.
19. Install the 17 transfer case bolts.
- Tighten to 25 Nm (18 lb-ft) evenly in a star pattern.
20. Using the Drive Pinion Flange Holding Fixture to hold the output flange, install the nut.
- Tighten to 355 Nm (262 lb-ft).
21. Install the transfer case in the vehicle. For additional information, refer to Transfer Case Transfer Case - Installation.
22. Fill the transfer case. For additional information, refer to Transfer Case Draining and Filling Procedures.