TRANSFER CASE REMOVAL
| CAUTION | ATF circulates between transaxle and transfer case. In situations where transaxle related failures circulate debris into transfer case, transfer case must be disassembled, cleaned, and inspected for damage. |
- Remove output shaft snap ring. (Scheme 67) Rotate transaxle 90 degrees. Remove transfer case lower brace bolt. (Scheme 68) Rotate transaxle 90 degrees.
- Remove transfer case side brace. (Scheme 69) Remove transfer case-to-transaxle bolts. (Scheme 70)
- Remove transfer case assembly from transaxle. (Scheme 71) Remove transfer case lower brace. (Scheme 72) Remove case extension seal from transfer case. (Scheme 73)
- Position transaxle with case side cover facing down. Remove oil dam from transaxle. (Scheme 74) Install transfer case assembly onto Holding Fixture (J 44755). (Scheme 75)
- Using Slide Hammer (J-6125-1B) and Adapter (J-44467), remove output shaft. (Scheme 76) Remove final drive sun gear. (Scheme 77)
- Remove sun gear thrust washer from transaxle. (Scheme 78) Remove parking gear and thrust bearing. (Scheme 79) Remove final drive sun gear shaft. (Scheme 80)
Scheme 67
Scheme 68
Scheme 69
Scheme 70
Scheme 71
Scheme 72
Scheme 73
Scheme 74
Scheme 75
Scheme 76
Scheme 77
Scheme 78
Scheme 79
Scheme 80
Input Shaft Oil Seal Ring Replacement
- Remove solid oil seal rings from input shaft. Inspect seal ring grooves for nicks or burrs. Lubricate each oil seal ring, and position individually onto Seal Protector (J-34741-1). (Scheme 81)
- Quickly slide each seal into ring groove when protector is in position. Using Seal Driver (J-34741-2), push ring over seal protector. Size seal with Seal Sizer (J-34741-3). Gently twist seal sizer over each seal. Leave sizer in place until input clutch housing installation.
Scheme 81
Bearing Replacement
Note. When installing NEW bearing, part number should be visible (facing upward).
Place case cover on clean flat surface with spacer plate mating surface up. Using Driver Handle (J-8092), Bearing Remover/Installer (J-41991) and hammer, drive out bearing from case cover. see scheme 160 To install, place case cover on clean flat surface with case mating surface up. Drive bearing into case cover. see scheme 161
TRANSFER CASE INSTALLATION
- Install case extension seal. (Scheme 73) Line up notch to hole in case and install oil dam. (Scheme 74)
- Install transfer case lower brace. (Scheme 72) Install and hand tighten transfer case lower brace bolts. Rotate transaxle so oil pan is facing floor. Install transfer case assembly onto transaxle. (Scheme 82)
- Install 5 transfer case-to-transaxle bolts. (Scheme 70) Torque bolts in sequence. Tighten transfer case bolts No. 1 and 2 in 2 passes; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 160 degrees. Tighten transfer case bolt No. 3; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 70 degrees. Tighten transfer case bolts No. 4 and 5 to 30 ft. lbs. (40 N.m).
- Install transfer case side brace to case and hand tighten bolts. Tighten bolts to 23 ft. lbs. (31 N.m) in numerical sequence (1, 2, 3, 4, 5). (Scheme 69) Install transfer case lower brace-to-transaxle bolt and tighten to 42 ft. lbs. (56 N.m) (Scheme 68) Tighten transfer case lower brace-to-transaxle bolts to 23 ft. lbs. (31 N.m).
- Affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to hard during installation of output shaft, or damage to bushings or bearings may occur. Carefully install output shaft into transaxle. Extend shaft through differential side gear.
