Necessary equipment
- J-25070 Jet dryer
- DT-48076 Stone guard installer
- DT-48094 Input shaft seal guard
Assembly order
1. Install dowel pins (1) distribution box halves.
2. install shaft (2) rear output drive transfer case and input shaft (3) transfer case in one set when the splines are engaged.
3. Install transfer case seal (4) to the distribution box (5).
4. Install 11 bolts (6) fastening halves of the transfer case.
Tighten
Tighten the bolts (6) fastening halves of the transfer case with a torque of 29 Nm (21 lb-ft).
5. Install new sealing ring (1) crankcase of the shaft of the rear output drive of the transfer case.
6. Install shim (2) rear output shaft of the transfer case.
Important: Do not use a driving hammer when the splines are not engaged. Using a driving hammer when the splines are not engaged will damage the teeth on the drive output shaft.
Important: The use of a jet dryer makes it easier to align the bolt holes relative to the crankcase during assembly.
7. Heat the drive housing flange area with a J-25070 jet dryer to facilitate installation of the housing (3) shaft of the rear output drive of the transfer case.
8. While rotating the planet gear during assembly to engage the gear teeth, install the rear output drive housing.
9. Install bolts (4) crankcase of the shaft of the rear output drive of the transfer case.
Tighten
Tighten the bolts (4) crankcase of the shaft of the rear output drive of the transfer case with a torque of 29 Nm (21 lb-ft).
Important: Keep in mind that the length of the layshaft varies depending on whether it is intended for manual or automatic transaxle. Choose a shaft of the required length. Otherwise, incorrect selection will result in wear of the intermediate shaft.
10. Heat the end of the transfer case case with a J-25070 jet dryer to facilitate installation of the front wheel drive intermediate shaft.
11. Install the front wheel drive intermediate shaft (1) with DT-48094 to prevent damage to the intermediate shaft seal.
12. Install retainer (2) front wheel drive intermediate shaft.
13. Install the guard using the DT-48076 stone guard installer (3) front wheel drive shaft.
14. Install O-ring (1) distribution box.
15. Install stopper (3) drain hole of the transfer case.
Tighten
Tighten the plug (3) drain hole of the transfer case with a torque of 39 Nm (29 lb-ft).
16. Pour transfer case fluid through the filler hole (2). See «Transfer case fluid change» in this section.
17. Install stopper (2) filler hole of the transfer case.
Tighten
Tighten the plug (2) filler hole of the transfer case with a torque of 39 Nm (29 lb-ft).
18. Install heat shield (4) and bolts for securing the heat shield of the transfer case.
Tighten
Tighten the transfer box heat shield mounting bolts to 11 Nm (97 lb-ft).
19. Install the transfer box on the vehicle. See «Transfer case» in this section.