REMOVAL & INSTALLATION
See Figure 1
- Drain the gear oil from the transaxle and the transfer case.
- Disconnect and remove the forward exhaust pipe.
- Using chalk or paint, matchmark the flanges on the driveshaft and then unbolt and remove the driveshaft from the transfer case.
- Unbolt and remove the transfer control actuator from the side of the transfer case.
- Disconnect and remove the right side halfshaft.
- Unscrew and withdraw the speedometer pinion gear from the transfer case. Position it out of the way and secure it with wire.
- Unbolt and remove the front, rear and side transfer case gussets (support members).
- Use an hydraulic floor jack and a block of wood to support the transfer case, remove the transfer case-to-transaxle mounting bolts and then remove the case itself. Be careful when moving it while supported on the jack.
- Install the transfer case in the vehicle. Tighten the transfer case-to-transaxle mounting bolts and the transfer case gusset mounting bolts to 22-30 ft. lbs. (30-40 Nm).
- Be sure to use a multi-purpose grease to lubricate all oil seal surfaces prior to reinstallation.
- Install the speedometer pinion gear.
- Install the halfshaft.
- Connect the transfer control actuator to the side of the transfer case.
- Install the driveshaft to the transfer case.
- Install the forward exhaust pipe.
- Refill all fluid levels, the transfer case and the transaxle use different types and weights of lubricant then road test for proper operation.