Honda Pilot - 2003-2005

Transfer Case Unit


Removal & Installation

  1. Before servicing the vehicle, refer to the precautions section.
  3. Drain the transmission fluid.
  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


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