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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