Mitsubishi Outlander 2003-06

Transfer Case Removal & Installation

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

    Engine undercover(s)
     
    Front exhaust pipe
     
    Propeller shaft
     
    Center member
     
    Air guide
     
    Halfshaft and output shaft
     
    Rear roll stopper bolt and nut
     
    Transfer case mounting bolts. Use a suitable tool to slide the transaxle to the front of the vehicle to make a suitable opening between the transaxle and crossmember. Pull the transfer case out of the opening.
     

  6.  


    Click image to see an enlarged view

    Fig. Exploded view of the transfer case


To install:

  1. Install or connect the following:

    Transfer case to the transaxle. Torque the bolts to 44-58 ft. lbs. (60-78 Nm).
     
    Rear roll stopper bolt and nut hand-tight. After the full weight of the vehicle is on the ground, torque the nut to 34-44 ft. lbs. (45-59 Nm).
     
    Halfshaft and output shaft
     
    Air guide and torque to 35-53 inch lbs. (4-6 Nm).
     
    Center member
     
    Propeller shaft
     
    Front exhaust pipe
     
    Engine undercover(s)
     

  2.  
  3. Fill the transaxle and the transfer case to the correct level.
  4.  

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

    Engine undercover(s)
     
    Front exhaust pipe
     
    Propeller shaft
     
    Center member
     
    Air guide
     
    Dust seal guard, manual transaxle
     
    Halfshaft and output shaft
     
    Rear roll stopper bolt and nut
     
    Transfer case mounting bolts. Use a suitable tool to slide the transaxle to the front of the vehicle to make a suitable opening between the transaxle and crossmember. Pull the transfer case out of the opening.

    Click image to see an enlarged view

    Fig. Transfer case and related components-vehicles with automatic transaxle



    Click image to see an enlarged view

    Fig. Transfer case and related components-vehicles with manual transaxle

     

  6.  

To install:

  1. Install or connect the following:

    Transfer case to the transaxle. Torque the bolts to 44-58 ft. lbs. (60-78 Nm).
     
    Rear roll stopper bolt and nut hand-tight. After the full weight of the vehicle is on the ground, torque the nut to 34-44 ft. lbs. (45-59 Nm).
     
    Halfshaft and output shaft
     
    Air guide
     
    Dust seal guard, manual transaxle
     
    Center member
     
    Propeller shaft
     
    Front exhaust pipe
     
    Engine undercover(s)
     

  2.  
  3. Fill the transaxle and the transfer case to the correct level.
  4.  

 
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