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    Mitsubishi Endeavor 2004-06

    Transfer Case Removal & Installation

    Print

    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the transmission and transfer case fluid. Drain the engine coolant.
    4.  
    5. Remove or disconnect the following:

      Engine under cover
       
      Front exhaust pipe
       
      Front propeller shaft
       
      Driveshaft and output shaft
       
      Right exhaust manifold stay -B-
       
      Air guide
       
      Water feed tube assembly and gasket
       
      Water return hose and gasket
       
      Retaining bolts and detach the transfer case assembly from the transmission. Lower the transfer case between the engine and crossmember. Remove and discard the O-rings.
       
      Water feed hose
       
      Air cleaner assemby
       
      Battery and battery tray
       
      Water return hose
       

    6.  


      Click image to see an enlarged view

      Fig. Exploded view of the transfer case assembly


    To install:

    1. Install or connect the following:

      Water return hose
       
      Battery tray and battery
       
      Air cleaner assemby
       
      Water feed hose
       
      New O-rings onto the transfer case
       
      Transfer case, by maneuvering it up between the engine and crossmember. Tighten the retaining bolts to 51 ft. lbs. (69 Nm).
       
      Water return hose gasket and hose
       
      Water feed tube gasket and tube
       
      Air guide
       
      Right exhaust manifold stay -B-
       
      Driveshaft and output shaft
       
      Front propeller shaft
       
      Front exhaust pipe
       
      Engine under cover
       

    2.  
    3. Fill the engine cooling system. Fill the transmission and transfer case with fluid.
    4.  

    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Drain the transaxle and transfer case fluid. Drain the engine coolant.
    4.  
    5. Remove or disconnect the following:

      Engine under cover
       
      Front exhaust pipe
       
      Front propeller shaft
       
      Driveshaft and output shaft
       
      Right exhaust manifold stay -B-
       
      Air guide
       
      Water feed tube assembly and gasket
       
      Water return hose and gasket
       
      Retaining bolts and detach the transfer case assembly from the transaxle. Lower the transfer case between the engine and crossmember. Remove and discard the O-rings.
       

    6.  
    7. As necessary, remove the water feed hose, air cleaner assembly, water return hose, battery and battery tray.

      Click image to see an enlarged view

      Fig. Transfer case and related components

    8.  

    To install:

    1. Install or connect the following:

      Water return hose
       
      Battery tray and battery
       
      Air cleaner assembly
       
      Water feed hose
       
      New O-rings onto the transfer case
       
      Transfer case, by maneuvering it up between the engine and crossmember. Tighten the retaining bolts to 51 ft. lbs. (69 Nm).
       
      Water return hose gasket and hose
       
      Water feed tube gasket and tube
       
      Air guide
       
      Right exhaust manifold stay -B-
       
      Driveshaft and output shaft
       
      Front propeller shaft
       
      Front exhaust pipe
       
      Engine under cover
       

    2.  
    3. Fill the engine cooling system. Fill the transaxle and transfer case with the proper grade and type fluid.
    4.  
    5. Connect the negative battery cable. On 2005-2006 vehicles, turn the ignition ON and then OFF , and keep it off for at least ten seconds.
    6.  

     
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