Mazda Trucks 1994-1998 Repair Guide

Transfer Case Assembly

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REMOVAL & INSTALLATION



See Figures 1, 2 and 3



Click image to see an enlarged view

Fig. Fig. 1: Exploded view of the 13-54 mechanical shift transfer case



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Fig. Fig. 2: Exploded view of the 13-54 electronic shift transfer case


CAUTION
The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the extremely high temperatures generated by the converter.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the vehicle and support it safely.
  4.  
  5. If so equipped, remove the skid plate from frame.
  6.  
  7. Drain the transfer case.
  8.  
  9. Remove the damper from the transfer case, if so equipped.
  10.  
  11. On electronic shift models, remove the wire connector from the feed wire harness at the rear of the transfer case. Be sure to squeeze the locking tabs, then pull the connectors apart.
  12.  
  13. Disconnect the front driveshaft from the axle input yoke.
  14.  
  15. If equipped, loosen the clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft.
  16.  
  17. Disconnect the rear driveshaft from the transfer case output shaft yoke.
  18.  
  19. If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
  20.  
  21. If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
  22.  
  23. Disconnect the vent hose from the mounting bracket.
  24.  
  25. On manual shift models, perform the following:
    1. Remove the shift lever retaining nut and remove the lever.
    2.  
    3. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
    4.  

  26.  
  27. If equipped, remove the heat shield from the transfer case.
  28.  
  29. Support the transfer case with a transmission jack.
  30.  
  31. Remove the mounting bolts retaining the transfer case to the transmission.
  32.  
  33. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket or any old sealer from between the transfer case and the transmission.
  34.  

To install:


Click image to see an enlarged view

Fig. Fig. 3: Case-to-extension bolt torque sequence-Navajo and B Series Pick-up

  1. Install the heat shield onto the transfer case, if equipped, and place a new gasket or silicone sealer between the transfer case and adapter.
  2.  
  3. Raise the transfer case with a suitable transmission jack or equivalent, raise it high enough so that the transmission output shaft aligns with the splined transfer case input shaft.
  4.  
  5. Slide the transfer case forward on to the transmission output shaft and onto the dowel pin. Install transfer case retaining bolts and torque them to specification. Tighten the mounting bolts to 35-46 ft. lbs. (47-63 Nm) on Navajo/B Series Pick-ups and 27-39 ft. lbs. (37-52 Nm) on MPVmodels.
  6.  
  7. The remainder of the installation procedure is the reverse of removal. Check the fluid level and, if necessary, top off with the correct amount and type of transfer case fluid.
  8.  

ADJUSTMENTS



Manual Shift Models

See Figure 4



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Fig. Fig. 4: Exploded view of the manual shift transfer case controls

The following procedure should be used, if a partial or incomplete engagement of the transfer case shift lever detent is experienced or if the control assembly requires removal.

  1. Disconnect the negative battery cable.
  2.  
  3. Raise the shift boot to expose the top surface of the cam plates.
  4.  
  5. Loosen the 1 large and 1 small bolt, approximately 1 turn. Move the transfer case shift lever to the 4L position (lever down).
  6.  
  7. Move the cam plate rearward until the bottom chamfered corner of the neutral lug just contacts the forward right edge of the shift lever.
  8.  
  9. Hold the cam plate in this position and torque the larger bolt first to 70-90 ft. lbs. (95-122 Nm) and torque the smaller bolt to 31-42 ft. lbs. (42-57 Nm).
  10.  
  11. Move the transfer case in cab shift lever to all shift positions to check for positive engagement. There should be a clearance between the shift lever and the cam plate in the 2H front and 4H rear (clearance not to exceed 3.3mm) and 4L shift positions.
  12.  
  13. Install the shift boot assembly.
  14.  
  15. Reconnect the negative battery cable.
  16.  

Except Manual Shift Models

Both of the electronic shift and the AWD model transfer cases do not require any linkage adjustments, nor are any possible.

 
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