Kia Sorento 2003-05

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 fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the front and rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside. Open the shift boot.
  8.  
  9. Loosen the transfer case shift lever locknut and remove the lever knob.
  10.  
  11. Pull the console up to access the wiring connector(s). Unplug the connector(s) and remove the console.
  12.  
  13. Shift the transfer lever to the 4L position.
  14.  
  15. Remove the cover plate.
  16.  
  17. Remove the retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission.
  18.  
  19. Matchmark the driveshafts at the flanges and remove the driveshafts.
  20.  
  21. Remove the crossmember bolts and support the transmission on the jack.
  22.  
  23. Disconnect the 4WD light switch connector.
  24.  
  25. Remove the transfer case mounting bolts.
  26.  
  27. Remove the crossmember.
  28.  
  29. Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area.
  30.  
  31. Lower the transfer case from the vehicle.
  32.  


    Click image to see an enlarged view

    Fig. Transfer case and crossmember location


To install:

  1. Install the transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm).
  2.  
  3. Install the crossmember.
  4.  
  5. Connect the 4WD light switch connector.
  6.  
  7. Align the matchmarks on the driveshafts to the flanges. Torque the bolts to 27 ft. lbs. (36 Nm) and remove the transmission support
  8.  
  9. Install the retaining bolts to the transfer case and install the shift lever assembly.
  10.  
  11. Remove the transmission support jack.
  12.  
  13. Install the cover plate.
  14.  
  15. Install the floor console unit and connect or install the following:

    Switch wiring connector(s)
     
    Front console
     
    Lever knob
     
    Front console and tie the shift boot draw strings
     
    Slide the console over the parking brake handle
     

  16.  
  17. Connect the negative battery cable
  18.  
  19. Fill the transfer case to the proper level
  20.  
  21. Start the vehicle and check for leaks, repair if necessary.
  22.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the transfer case fluid.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the front and rear console mounting screws. Slide the console forward to clear the parking brake handle and set aside. Open the shift boot.
  8.  
  9. Loosen the transfer case shift lever locknut and remove the lever knob.
  10.  
  11. Pull the console up to access the wiring connector(s). Unplug the connector(s) and remove the console.
  12.  
  13. Shift the transfer lever to the 4L position.
  14.  
  15. Remove the cover plate.
  16.  
  17. Remove the retaining bolts from the transfer case and lift the shifter lever assembly straight out and properly support the transmission.
  18.  
  19. Matchmark the driveshaft at the flanges and remove the driveshaft.
  20.  
  21. Remove the crossmember bolts and support the transmission on the jack.
  22.  
  23. Disconnect the 4WD light switch connector.
  24.  
  25. Remove the transfer case mounting bolts.
  26.  
  27. Remove the crossmember.
  28.  
  29. Separate the transfer case from the transmission by striking the transfer case with a plastic mallet at the seal area.
  30.  
  31. Lower the transfer case from the vehicle.

    Click image to see an enlarged view

    Fig. Transfer case and crossmember location

  32.  

To install:

  1. Install the transfer case in position with a new gasket. Torque the bolts to 32 ft. lbs. (44 Nm).
  2.  
  3. Install the crossmember.
  4.  
  5. Connect the 4WD light switch connector.
  6.  
  7. Align the matchmarks on the driveshaft to the flanges. Torque the bolts to 27 ft. lbs. (36 Nm) and remove the transmission support
  8.  
  9. Install the retaining bolts to the transfer case and install the shift lever assembly.
  10.  
  11. Remove the transmission support jack.
  12.  
  13. Install the cover plate.
  14.  
  15. Install the floor console unit and connect or install the following:

    Switch wiring connector(s)
     
    Front console
     
    Lever knob
     
    Front console and tie the shift boot draw strings
     
    Slide the console over the parking brake handle
     

  16.  
  17. Connect the negative battery cable
  18.  
  19. Fill the transfer case to the proper level
  20.  
  21. Start the vehicle and check for leaks, repair if necessary.
  22.  

 
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