Volvo 240/740/760/780/940/960 1990-1998

Transfer Case Assembly

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REMOVAL & INSTALLATION



See Figures 1 and 2

  1. Raise and safely support the vehicle.
  2.  
  3. Remove the right front wheel.
  4.  
  5. Remove the passenger side halfshaft from the transfer case.
  6.  
  7. Remove the transfer case vibration damper with support bracket.
  8.  
  9. Mark the flange, and remove the rear driveshaft from the transfer case.
  10.  
  11. Remove the transfer case-to-transaxle retaining bolts.
  12.  
  13. Remove the transfer case.
  14.  

To install:
  1. Install the transfer case on the transaxle. Make sure that the coupling sleeve is between the transaxle and the transfer case.
  2.  
  3. Tighten the retaining bolts to 37 ft. lbs. (50 Nm).
  4.  
  5. Install the rear driveshaft.
  6.  
  7. Install the vibration damper and bracket.
  8.  
  9. Install the passenger side halfshaft.
  10.  
  11. Install the right front wheel. Tighten the lug nuts to 81 ft. lbs. (110 Nm).
  12.  
  13. Lower the vehicle.
  14.  



Click image to see an enlarged view

Fig. Fig. 1: The transfer case (1) as assembled to the transaxle (2)



Click image to see an enlarged view

Fig. Fig. 2: Cutaway view of power distribution through a transfer case

 
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