TRANSFER BOX (ATC 500 X-DRIVE TRANSFER BOX)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 2) Use only the approved gear oil. See TRANSFER CASE - SERVICING article.
Scheme 2
On 4.4L, remove catalytic converter. See EXHAUST SYSTEM . On all models, remove front and rear heat shields.
Grip clamping sleeve (1) and slacken nut (2). Pull out retainer (3) using a screwdriver. (Scheme 3) NOTE: During installation, adjust selector lever. See ADJUSTING SELECTOR LEVER.
Scheme 3
Remove propeller shaft from transmission. Release center bearing. Tie propeller shaft to one side. Support automatic transmission with hydraulic lifter. Unfasten screws and remove transmission crossmember (1). (Scheme 4)
Scheme 4
Detach plugs (1) and (2) from servomotor. (Scheme 5)
Scheme 5
Release screw connection of transfer case. Remove transfer case. During installation, pay attention to dowel pin (1). Grease dowel pin (1). (Scheme 6) Apply a thin coat of Weicon anti-seize grease to splines.
Scheme 6
TRANSFER CASE (A/T)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 2) See TRANSFER CASE - SERVICING article.
Move selector lever to park position "P". Remove exhaust system. See EXHAUST SYSTEM. Remove bolts (1) and (2) and remove reinforcement plate. (Scheme 7) Do not drive vehicle while reinforcement plate is removed.
Scheme 7
Remove heat shields. Unclip cables for oxygen sensors. Release stabilizer bar. See STABILIZER BAR .
Remove heat shield at rear. (Scheme 8) Remove front propeller shaft. See FRONT PROPELLER SHAFT.
Scheme 8
Grip clamp bushing (1) and slacken nut (2). (Scheme 9)
Scheme 9
During installation, adjust selector lever. See ADJUSTING SELECTOR LEVER. Grip cable (1) at hexagon (2). Release nut (3). Pull cable (1) out of holder. (Scheme 10)
Scheme 10
On automatic transmission (A5S 440Z-5HP24), support transmission with special tool (00 2 030/24 5 301/24 0 250). (Scheme 11)
Scheme 11
On automatic transmission A5S 360R-GM5, support transmission with special tools (00 2 030/24 5 301/24 5 305). (Scheme 12)
Scheme 12
Unclip oxygen sensor cable at transmission crossmember. Release screws and remove transmission crossmember. (Scheme 13)
Scheme 13
Detach vent line (1). Unclip oxygen sensor cable at transfer case. (Scheme 14)
Scheme 14
Release bolts. (Scheme 15) During installation, replace self-locking nuts. Only tighten screw connection by way of nut. This prevents the flexible disk from being subjected to torsion stress.
Scheme 15
Grip propeller shaft at center mount and release nuts. (Scheme 16)
Scheme 16
During installation, center mount must be aligned at right angles to propeller shaft. DO NOT let propeller shaft fall into joints as joints and rubber sleeve can be damaged on constant-velocity joint. (Scheme 17)
Scheme 17
Bend propeller shaft downward at center mount. (Scheme 18)
Scheme 18
Remove propeller shaft from transmission output flange and tie back to one side with cord or wire. Take up transfer case (1) with special tools (27 1 100). (Scheme 19)
Scheme 19
Release transfer case screw connection on transmission. Remove transfer case. During installation, pay attention to dowel sleeves. (Scheme 20) Replace damaged dowel sleeves. Apply a thin coat of Weicon antisize grease to splines.
Scheme 20
TRANSFER CASE (M/T)
Note. Numbers in text refer to numbers in figures.
Note. After completing work, check gear oil level and top up if necessary. Tighten filler plug (1) as necessary. See TORQUE SPECIFICATIONS. Fill gear oil level up to filler edge of filler plug (1). (Scheme 2) Use only the approved gear oil. See TRANSFER CASE - SERVICING article.
Remove exhaust system. See EXHAUST SYSTEM. Remove heat shield at rear. Remove bolts (1, 2) and remove reinforcement plate. (Scheme 7) Do not drive vehicle while reinforcement plate is removed. Release stabilizer bar. See STABILIZER BAR. Remove front propeller shaft. See FRONT PROPELLER SHAFT.
On manual transmission (S5D 280Z), support transmission with special tools (00 2 030 and 23 0 130). (Scheme 21)
Scheme 21
Release screws and remove transmission crossmember. (Scheme 13)
Detach vent line (1). Unclip cable from transfer case. (Scheme 14)
Release screws. During installation, replace self-locking nuts. When tightening screws down, grip each screw and tighten down nut. This prevents the flexible disk from being subjected to torsion stress. (Scheme 15)
Grip propeller shaft at center mount and release nuts. During installation, center mount must be aligned at right angles to propeller shaft. (Scheme 16) DO NOT let propeller shaft fall into joints. (Scheme 17) Joints and rubber sleeve can be damaged on constant-velocity joint.
Bend propeller shaft downwards at center mount, remove from transmission output flange and tie back to one side with cord or wire. (Scheme 18)
Take up transfer case with special tools (27 1 100 and 00 2 030). Release transfer case screw connection on transmission. Remove transfer case. (Scheme 19)
During installation, note dowel sleeves. (Scheme 20) Replace damaged dowel sleeves. Apply a thin coat of Weicon antisize grease to splines. Replace sealing ring (1) on drive shaft (2) of transfer case. (Scheme 22)
