Mitsubishi Endeavor 2004-06

Transfer Case Removal & Installation

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  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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