Honda Pilot - 2003-2005

Transfer Case Unit

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Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2.  
  3. Drain the transmission fluid.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Front sub-frame stiffener
     
    Exhaust front pipe
     
    Breather tube bracket bolt, then the tube from the breather pipe
     
    Propeller shaft from the transfer assembly
     
    Transfer assembly bolts and the assembly
     

  6.  

To install:

  1. Install or connect the following:

    New O-ring on the transfer cover
     
    Dowel pin on the assembly
     
    Transfer assembly and tighten the bolts to 33 ft. lbs. (44 Nm) in a star pattern
     
    Propeller shaft
     
    Breather tube bracket, attach the tube with the dot facing outwards and tighten the bolt to 9 ft. lbs. (12 Nm)
     
    Exhaust front pipe
     
    Front sub-frame stiffener and tighten the bolts to 40 ft. lbs. (54 Nm)
     
    Heated Oxygen (HO 2 S) sensor connectors
     
    Negative battery cable
     

  2.  

 
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