Transfer Case
Under normal driving conditions, replace transfer case fluid every 60,000 miles. Under severe driving conditions, per-form this service more frequently.
Remove fill plug. If fluid drains out or is level with opening, reinstall drain plug. If not, fill until level.
E4OD
- Raise and support vehicle. Place drain pan under transmission pan. Remove rear and side drain pan bolts. Loosen front drain pan bolt to allow fluid to drain. Remove front drain pan bolts. Remove drain pan and gasket.
- Remove and discard oil screen and seal. If seal remains in bore, carefully remove using a screwdriver. Install NEW oil screen and seal, using clean ATF to lubricate seal. Clean oil pan, and install pan using NEW gasket. Fill transmission through filler tube. Start engine and engage all gears. Check fluid level and add as required.
Remove drain plug from transfer case. Remove fill plug for easier draining. With fluid fully drained, reinstall drain plug. Fill transfer case to fill plug opening with Mercon ATF.
Note. Transmission oil cooler and lines should be thoroughly flushed if transmission is removed for any reason. Use appropriate line disconnecting tool when disconnecting cooler lines.
BAND
| CAUTION | DO NOT allow adjustment screw to back out. Band strut could fall inside transmission assembly. |
SHIFT CABLE/LINKAGE
- Place shift control selector in "OD" position. Hold shift lever against rear of stop with a constant force of about 3 lbs. (1.4 kg). Raise and support vehicle. Remove shift cable from control lever ball stud on transmission.
- Pull down lock tab on shift cable body. Move shift cable back and forth the full adjustment length a few times to remove any dirt. Ensure adjuster body moves freely.
- Position manual control lever in "OD" position. This is 3 detents from front-most position with front position counting as one. Holding cable end, push cable rearward until end lines up with ball stud. Connect cable to ball stud.
- Push up on lock tab to lock adjustment sleeve in position. Ensure shift cable is clipped to floor pan at White mark on cable and cable is routed into tunnel. Lower vehicle. Adjust shift indicator cable while still in OVERDRIVE position. See «SHIFT INDICATOR CABLE»(ref-58610-S19809593442001011800000) .
- Remove pressure from shift control selector. Check PARK engagement. Start engine and ensure transmission shifts through all gears. Verify vehicle only starts in "P" and "N" position and backup lights work. If not, check transmission range sensor adjustment. See «TRANSMISSION RANGE (TR) SENSOR/SWITCH»(ref-58610-S00445021452001011800000) .
SHIFT INDICATOR CABLE
- Remove lower steering column cover. Move shift control selector until in lowest gear position. Move shift control lever up 3 detent positions.
- Hold shift lever against rear of stop with a constant force of about 3 lbs. (1.4 kg). Center pointer in middle of "OD" position, by rotating thumbwheel located on right side of steering column. Remove pressure from shift control selector and install lower steering column cover.
TRANSMISSION RANGE (TR) SENSOR/SWITCH
- Remove nut securing manual control lever to Transmission Range (TR) sensor. Turn manual lever to NEUTRAL position. Loosen bolts securing TR sensor to transaxle. Using appropriate TR sensor alignment tool, align TR sensor slots. Tighten TR sensor mounting bolts.
- Install manual lever retaining nut. Tighten nut to specification. See «TORQUE SPECIFICATIONS»(ref-58610-S28238539972001011800000) . Check PARK engagement. Start engine and ensure transmission shifts through all gears. If not, check shift cable adjustment. See «SHIFT CABLE/LINKAGE»(ref-58610-S14980696292001011800000) . Verify vehicle only starts in "P" and "N" positions and backup lights work.
SHIFT INTERLOCK SYSTEMS
Note. For information on shift interlock systems, see the SHIFT INTERLOCK SYSTEM article in AUTO TRANS DIAGNOSIS section.