AutoZone 2004 Audi S4 Quattro 4.2L SFI DOHC 8cyl | Repair Guides | Drive Train | Transfer Case | Transfer Case Removal & Installation | AutoZone.com

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    2004 Audi S4 Quattro 4.2L SFI DOHC 8cyl

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    Kia Sportage 1998-02

    Transfer Case Removal & Installation

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    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2.  
    3. Drain the transfer case.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Two rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside
       
      Three mounting screws from the front console. Untie the shift boot draw strings and open the boot
       
      Loosen the transfer case shift lever locknut and remove the lever knob
       
      Pull the console up to access the Power/Economy switch wiring connector. Unplug the connector and remove the console
       

    6.  
    7. Shift the transfer lever to the 4L position.

      Cover plate
       
      Retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission
       
      Matchmark the driveshafts at the flanges and remove the driveshafts
       
      Crossmember bolts
       
      4WD light switch connector
       
      Transfer case mounting bolts located at the right center of the transfer case
       
      Transfer case nuts from the crossmember
       
      Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area
       

    8.  
    9. Lower the transfer case from the vehicle.
    10.  

    To install:

    1. Install or connect the following:

      Transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm).
       
      Crossmember. Torque bolts to 32 ft. lbs. (44 Nm).
       
      Transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 38 ft. lbs. (52 Nm).
       
      Four transfer case nuts to the crossmember. Torque the nuts to 15 ft. lbs. (20 Nm).
       
      Align the matchmarks on the driveshafts to the flanges. Torque the bolts to 27 ft. lbs. (36 Nm) and remove the transmission support
       
      4WD light switch electrical connector
       
      VSS electrical connector
       
      Shifter lever assembly. Torque retaining bolts to 20 ft. lbs. (27 Nm).
       
      Cover plate. Torque the bolts to 15 ft. lbs. (20 Nm).
       
      Power/Economy switch wiring connector
       
      Front console
       
      Lever knobs
       
      Front console and tie the shift boot draw strings
       
      Slide the console over the parking brake handle
       
      Rear console
       
      Negative battery cable
       

    2.  
    3. Fill the transfer case to the proper level
    4.  
    5. Start the vehicle and check for leaks, repair if necessary.
    6.  


      Click image to see an enlarged view

      Fig. Exploded view of the transfer case assembly


    1. Before servicing the vehicle, refer to the precautions in the beginning of this section .
    2.  
    3. Drain the transfer case.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Two rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside
       
      Three mounting screws from the front console. Untie the shift boot draw strings and open the boot
       
      Loosen the transfer case shift lever locknut and remove the lever knob
       
      Pull the console up to access the Power/Economy switch wiring connector. Unplug the connector and remove the console
       

    6.  
    7. Shift the transfer lever to the 4L position.

      Cover plate
       
      Retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission
       
      Matchmark the driveshafts at the flanges and remove the driveshafts
       
      Crossmember bolts
       
      4WD light switch connector
       
      Transfer case mounting bolts located at the right center of the transfer case
       
      Transfer case nuts from the crossmember
       
      Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area
       

    8.  
    9. Lower the transfer case from the vehicle.
    10.  

    To install:

    1. Install or connect the following:

      Transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm).
       
      Crossmember. Torque bolts to 32 ft. lbs. (44 Nm).
       
      Transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 38 ft. lbs. (52 Nm).
       
      Four transfer case nuts to the crossmember. Torque the nuts to 15 ft. lbs. (20 Nm).
       
      Align the matchmarks on the driveshafts to the flanges. Torque the bolts to 27 ft. lbs. (36 Nm) and remove the transmission support
       
      4WD light switch electrical connector
       
      VSS electrical connector
       
      Shifter lever assembly. Torque retaining bolts to 20 ft. lbs. (27 Nm).
       
      Cover plate. Torque the bolts to 15 ft. lbs. (20 Nm).
       
      Power/Economy switch wiring connector
       
      Front console
       
      Lever knobs
       
      Front console and tie the shift boot draw strings
       
      Slide the console over the parking brake handle
       
      Rear console
       
      Negative battery cable
       

    2.  
    3. Fill the transfer case to the proper level
    4.  
    5. Start the vehicle and check for leaks, repair if necessary.

      Click image to see an enlarged view

      Fig. Exploded view of the transfer case assembly

    6.  

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the transfer case.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Two rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside
       
      Three mounting screws from the front console. Untie the shift boot draw strings and open the boot
       
      Loosen the transfer case shift lever locknut and remove the lever knob
       
      Pull the console up to access the Power/Economy switch wiring connector. Unplug the connector and remove the console
       

    6.  
    7. Shift the transfer lever to the 4L position.

      Cover plate
       
      Retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission
       
      Matchmark the driveshafts at the flanges and remove the driveshafts
       
      Crossmember bolts
       
      4WD light switch connector
       
      Transfer case mounting bolts located at the right center of the transfer case
       
      Transfer case nuts from the crossmember
       
      Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area
       

    8.  
    9. Lower the transfer case from the vehicle.
    10.  

    To install:

    1. Install or connect the following:

      Transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm)
       
      Crossmember. Torque bolts to 32 ft. lbs. (44 Nm)
       
      Transfer case mounting bolts located at the right center of the transfer case. Torque the bolts to 38 ft. lbs. (52 Nm)
       
      Four transfer case nuts to the crossmember. Torque the nuts to 15 ft. lbs. (20 Nm)
       
      Align the matchmarks on the driveshafts to the flanges. Torque the bolts to 27 ft. lbs. (36 Nm) and remove the transmission support
       
      4WD light switch electrical connector
       
      VSS electrical connector
       
      Shifter lever assembly. Torque retaining bolts to 20 ft. lbs. (27 Nm)
       
      Cover plate. Torque the bolts to 15 ft. lbs. (20 Nm)
       
      Power/Economy switch wiring connector
       
      Front console
       
      Lever knobs
       
      Front console and tie the shift boot draw strings
       
      Slide the console over the parking brake handle
       
      Rear console
       
      Negative battery cable
       

    2.  
    3. Fill the transfer case to the proper level
    4.  
    5. Start the vehicle and check for leaks, repair if necessary.

      Click image to see an enlarged view

      Fig. Exploded view of the transfer case assembly

    6.  

     
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