Mitsubishi Car 1999-05

Transfer Case Removal & Installation

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Fig. Transfer case assembly-F5M33, W5MG1 and W6MG1 transfer cases

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Raise the vehicle and support safely.
  6.  
  7. Disconnect the front exhaust pipe.
  8.  
  9. Unbolt the transfer case assembly and remove by sliding it off the rear driveshaft. Do not let the rear driveshaft hang; suspend it from a frame piece.
  10.  

To install:

  1. Install the transfer case assembly to the transaxle. Install the rear driveshaft to the transfer case output shaft.
  2.  
  3. Tighten the transfer case to transaxle bolts to 18-22 ft. lbs. (25-29 Nm).
  4.  
  5. Install the exhaust pipe using a new gasket.
  6.  
  7. Lower the vehicle and connect the negative battery cable.
  8.  

  1. Remove or disconnect the following:

    Engine undercovers
     
    Front exhaust pipe
     
    Transfer case mounting bolts
     

  2.  
  3. Support the driveshaft with wire or string and remove the transfer case from the transaxle.
  4.  

To install:

  1. Slide the driveshaft into the transfer case and install the transfer case to the transaxle. Torque the bolts to 40-44 ft. lbs. (54-59 Nm).
  2.  
  3. Install or connect the following:

    Front exhaust pipe
     
    Engine undercover
     

  4.  

Evolution



  1. Disconnect the negative battery cable. Remove the under cover assembly. Drain the transaxle fluid.
  2.  
  3. Drain the transfer case fluid. Drain the engine coolant.
  4.  
  5. Remove the front axle crossmember assembly.
  6.  
  7. Remove the front exhaust pipe. Remove the battery and the battery tray.
  8.  
  9. Remove the air cleaner and air intake hose assembly.
  10.  
  11. Remove the strut tower bar assembly.
  12.  
  13. Remove the air hose, air by-pass hose and air by-pass valve.
  14.  
  15. Remove the radiator.
  16.  
  17. Remove the output shaft. Remove the driveshaft.
  18.  
  19. Remove the rear roll stopper connection bolt. Remove the crossmember assembly.
  20.  
  21. Disconnect the pressure hose connection and discard the gasket.
  22.  
  23. Remove the dust seal guard.
  24.  
  25. Remove the transfer case retaining bolts. Remove the transfer case from the vehicle. Discard the O-ring.
  26.  

To install:

Click image to see an enlarged view

Fig. Transfer case and related components-Evolution

  1. Position the transfer case on a suitable holding fixture. Install the transfer case to its mounting in the vehicle.
  2.  
  3. Continue the installation in the reverse order of the removal procedure.
  4.  
  5. Be sure to check and adjust all fluid levels, as necessary.
  6.  

 
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