Volvo Truck 2003-05

Transfer Case Removal & Installation


  1. Before servicing the vehicle, refer to the Precautions Section.
  3. Remove or disconnect the following:
    Mark the driveshaft CV joint in relation to the transfer case assembly flange.

    Front right wheel and tire
    Front right halfshaft
    Engine splash guard
    The mounting for the center bearing for the driveshaft

    Bolts on driveshaft using counterhold 999 7057
    Press the driveshaft CV joints together and remove driveshaft
    Remove bolts holding the transfer case and pull it straight out from the transaxle assembly


To install:

Before installing the transfer case, lubricate the spline joint that joins to the transaxle. Make sure that the mating surfaces on the transaxle and transfer case are clean and not damaged.

  1. Use new bolts to attach transfer case. Tighten the bolts alternately to light contact. Then, tighten alternately to 37 ft. lbs. (50 Nm).
    Check carefully that the mating surfaces on the driveshaft CV joint and flange are clean.

  3. Install or connect the following:

    The driveshaft according to the previous marking. Use new bolts and counterhold 999 7057 to tighten driveshaft bolts to 18 ft. lbs. (24 Nm).
    The center bearing and member for the driveshaft. Use new bolts and tighten to 18 ft. lbs. (24 Nm).
    Right front halfshaft to the wheel hub. Refer to Halfshafts removal and installation

  5. Fill the transaxle with proper amount of oil.
  7. Check the oil level in the transfer case. Fill with oil up to the filling plug.
  9. Install engine splash guard.
  11. Install right front wheel and tire. Tighten lug nuts to 102 ft. lbs. (138 Nm).