Mazda Tribute 2001-06

Transfer Case Removal & Installation

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  1. Disconnect the battery.
  2.  
  3. Drain the transfer case.
  4.  
  5. Remove the driveshaft.
  6.  
  7. Remove the 4 bolts and the crossmember brace.
  8.  
  9. Remove the generator.
  10.  
  11. Disconnect the RH catalyst monitor.
  12.  
  13. Remove and discard the 2 nuts and separate the flexible Y-pipe from the manifold.
  14.  
  15. Remove and discard the nuts. Discard the gasket.
  16.  
  17. Remove and discard the nuts. Discard the gasket.
  18.  
  19. Remove the flexible pipe. Disconnect the hanger.
  20.  
  21. Disconnect the EGR valve to exhaust manifold tube at the manifold.
  22.  
  23. Disconnect the RH heated oxygen sensor.
  24.  
  25. Remove the RH exhaust manifold. Discard the gasket.
  26.  
  27. Remove the support bracket.
  28.  
  29. Remove the 3 transfer case bolts.
  30.  


NOTE
The transfer case driven gear seal must be replaced whenever the link shaft or transfer case is removed from the vehicle.


NOTE
If necessary, replace the RH differential fluid seal.

  1. Remove the bolt and the transfer case.
  2.  

To install:


NOTE
The transfer case driven gear seal must be replaced whenever the link shaft or transfer case is removed from the vehicle. If necessary, replace the RH differential fluid seal.

  1. Install the transfer case. Install the bolts. Torque to 33 ft. lbs. (45 Nm).
  2.  
  3. Install the side mount bolt. Torque to 33 ft. lbs. (45 Nm).
  4.  
  5. Install the bracket and the 6 bolts. Torque to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the RH exhaust manifold.
  8.  
  9. Connect the RH heated oxygen sensor.
  10.  
  11. Connect the EGR to exhaust manifold tube. Torque to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the flex pipe and connect the hanger.
  14.  
  15. Install the gasket and the nuts. Torque to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the flex pipe gasket and the nuts. Torque to 37 ft. lbs. (50 Nm).
  18.  
  19. Connect the flexible Y-pipe to the exhaust manifold and install the two nuts. Torque to 30 ft. lbs. (40 Nm).
  20.  
  21. Connect the RH catalyst monitor sensor.
  22.  
  23. Install the generator.
  24.  
  25. Install the crossmember brace and the four bolts. Torque to 30 ft. lbs. (40 Nm).
  26.  
  27. Check the transfer case fluid level.
  28.  
  29. Install the driveshaft.
  30.  
  31. Connect the battery ground cable.
  32.  
  33. Check the transaxle fluid level.
  34.  

Except 2.0L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Disconnect the battery.
  6.  
  7. Drain the transfer case.
  8.  
  9. Remove the driveshaft.
  10.  
  11. Remove the 4 bolts and the crossmember brace.
  12.  
  13. Remove the generator.
  14.  
  15. Disconnect the RH catalyst monitor.
  16.  
  17. Remove and discard the 2 nuts and separate the flexible Y-pipe from the manifold.
  18.  
  19. Remove and discard the nuts. Discard the gasket.
  20.  
  21. Remove and discard the nuts. Discard the gasket.
  22.  
  23. Remove the flexible pipe. Disconnect the hanger.
  24.  
  25. Disconnect the EGR valve to exhaust manifold tube at the manifold.
  26.  
  27. Disconnect the RH heated oxygen sensor.
  28.  
  29. Remove the RH exhaust manifold. Discard the gasket.
  30.  
  31. Remove the support bracket.
  32.  
  33. Remove the 3 transfer case bolts.
    NOTE
    The transfer case driven gear seal must be replaced whenever the link shaft or transfer case is removed from the vehicle.


    NOTE
    If necessary, replace the RH differential fluid seal.

  34.  
  35. Remove the bolt and the transfer case.
  36.  

To install:


NOTE
The transfer case driven gear seal must be replaced whenever the link shaft or transfer case is removed from the vehicle. If necessary, replace the RH differential fluid seal.

  1. Install the transfer case. Install the bolts. Torque to 33 ft. lbs. (45 Nm).
  2.  
  3. Install the side mount bolt. Torque to 33 ft. lbs. (45 Nm).
  4.  
  5. Install the bracket and the 6 bolts. Torque to 30 ft. lbs. (40 Nm).
  6.  
  7. Install the RH exhaust manifold.
  8.  
  9. Connect the RH heated oxygen sensor.
  10.  
  11. Connect the EGR to exhaust manifold tube. Torque to 30 ft. lbs. (40 Nm).
  12.  
  13. Install the flex pipe and connect the hanger.
  14.  
  15. Install the gasket and the nuts. Torque to 37 ft. lbs. (50 Nm).
  16.  
  17. Install the flex pipe gasket and the nuts. Torque to 37 ft. lbs. (50 Nm).
  18.  
  19. Connect the flexible Y-pipe to the exhaust manifold and install the two nuts. Torque to 30 ft. lbs. (40 Nm).
  20.  
  21. Connect the RH catalyst monitor sensor.
  22.  
  23. Install the generator.
  24.  
  25. Install the crossmember brace and the four bolts. Torque to 30 ft. lbs. (40 Nm).
  26.  
  27. Check the transfer case fluid level.
  28.  
  29. Install the driveshaft.
  30.  
  31. Connect the battery ground cable.
  32.  
  33. Check the transaxle fluid level.
  34.  

w/2.0L Engine



  1. Remove the driveshaft.
  2.  
  3. Remove the four bolts and remove the crossmember brace.
  4.  
  5. Remove the two bolts and the two nuts.
  6.  
  7. Remove the transfer case.
  8.  
  9. Remove and discard the O-ring seal.
  10.  

To install:

  1. Install a new O-ring seal.
  2.  
  3. Install the transfer case.
  4.  
  5. Install the two bolts and the two nuts. Torque to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the crossmember brace and the four bolts. Torque to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the driveshaft.
  10.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise and support the vehicle safely.
  4.  
  5. Remove the driveshaft.
  6.  
  7. Remove the four bolts and remove the crossmember brace.
  8.  
  9. Remove the two bolts and the two nuts.
  10.  
  11. Remove the transfer case.
  12.  
  13. Remove and discard the O-ring seal.
  14.  

To install:

  1. Install a new O-ring seal.
  2.  
  3. Install the transfer case.
  4.  
  5. Install the two bolts and the two nuts. Torque to 33 ft. lbs. (45 Nm).
  6.  
  7. Install the crossmember brace and the four bolts. Torque to 30 ft. lbs. (40 Nm).
  8.  
  9. Install the driveshaft.
  10.  

With Automatic Transaxle





Click image to see an enlarged view

Fig. Transfer case mounting with automatic transaxle-2005 model shown

  1. Disconnect the battery.
  2.  
  3. Drain the transfer case.
  4.  
  5. Remove the front RH intermediate shaft.
  6.  
  7. Remove the driveshaft.
  8.  
  9. Remove the 4 bolts and the crossmember brace.
  10.  
  11. Remove the generator.
  12.  
  13. Remove the exhaust as required.
  14.  
  15. Remove the heat shield.
  16.  
  17. Remove the transfer case-to-transaxle bolts.
  18.  
  19. Remove the transfer case.
  20.  


WARNING
A new transfer case driven gear seal must be installed whenever the intermediate shaft or transfer case is removed from the vehicle.


NOTE
If necessary, replace the RH differential fluid seal.

  1. To install, reverse the removal procedure. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
     
    Transfer case-to-transaxle bolts: 33 ft. lbs. (45 Nm).
     

  2.  



Click image to see an enlarged view

Fig. Automatic transaxle transfer case mounting-2005-2006 vehicles

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies, if equipped.

  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the transfer case.
  8.  
  9. Remove the front right side intermediate shaft.
  10.  
  11. Remove the driveshaft.
  12.  
  13. Remove the 4 bolts and the crossmember brace.
  14.  
  15. Remove the alternator.
  16.  
  17. Remove the exhaust as required.
  18.  
  19. Remove the heat shield.
  20.  
  21. Remove the transfer case-to-transaxle bolts.
  22.  
  23. Remove the transfer case.
  24.  

To install:


WARNING
A new transfer case driven gear seal must be installed whenever the intermediate shaft or transfer case is removed from the vehicle.


NOTE
If necessary, replace the right side differential fluid seal.

  1. To install, reverse the removal procedure. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
     
    Transfer case-to-transaxle bolts: 33 ft. lbs. (45 Nm).
     

  2.  
  3. Fill the transfer case with the proper grade and type fluid.
  4.  

With Manual Transaxle





Click image to see an enlarged view

Fig. Transfer case mounting with manual transaxle-2005 model shown

  1. Remove the driveshaft.
  2.  
  3. Remove the 4 bolts and the crossmember brace.
  4.  
  5. Remove the transfer case-to-transaxle bolts.
  6.  
  7. Remove the transfer case-to-transaxle nut.
  8.  
  9. Remove the transfer case.
  10.  
  11. To install, reverse the removal procedure.
  12.  


WARNING
The O-ring must be properly installed before mating the transfer case to the manual transaxle. Failure to properly install the O-ring may cause the O-ring to be damaged resulting in transaxle oil leak.

  1. Install a new O-ring seal. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
     
    Transfer case mounting nuts: 33 ft. lbs. (45 Nm).
     
    Transfer case mounting bolts: 33 ft. lbs. (45 Nm).
     

  2.  



Click image to see an enlarged view

Fig. Manual transaxle transfer case mounting-2005-2006 vehicles

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
    NOTE
    To deplete the backup power supply energy, disconnect the negative battery cable and wait at least one minute. Be sure to disconnect auxiliary batteries and power supplies, if equipped.

  4.  
  5. Raise and support the vehicle safely.
  6.  
  7. Drain the transfer case.
  8.  
  9. Remove the driveshaft.
  10.  
  11. Remove the 4 bolts and the crossmember brace.
  12.  
  13. Remove the transfer case-to-transaxle bolts.
  14.  
  15. Remove the transfer case-to-transaxle nut.
  16.  
  17. Remove the transfer case.
  18.  

To install:

  1. To install, reverse the removal procedure.
    WARNING
    The O-ring must be properly installed before mating the transfer case to the manual transaxle. Failure to properly install the O-ring may cause the O-ring to be damaged resulting in transaxle oil leak.

  2.  
  3. Install a new O-ring seal. Observe the following torques:

    Crossmember bolts: 30 ft. lbs. (40 Nm).
     
    Transfer case mounting nuts: 33 ft. lbs. (45 Nm).
     
    Transfer case mounting bolts: 33 ft. lbs. (45 Nm).
     

  4.  
  5. Fill the transfer case with the proper grade and type fluid.
  6.  

 
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