Reinstallation

7. Apply a coating of the recommended gear oil to the output seal (75W-85W GL4).

Apply grease to the splines of the transfer case output shaft.





8. Apply grease to the splines of the transaxle output shaft.





9. Remove the transfer case bracket from the old case. Apply thread locking compound on the mounting bolt and install the bracket onto the replacement transfer case assembly. Torque the bolt to: 25 N-m (18 ft.lbs.).





10. Enlist the help of an assistant for this step. Loosen (do not remove) the securing wire from the propeller shaft. Insert the propeller shaft into the transfer case, then, mount the transfer case onto the transaxle. Install and torque the transfer case mounting bolts to 87 N-m (65 ft.lbs.). Remove the wire supporting the propeller shaft from the vehicle.





11. Remove the transfer case fill plug.

Note:
Check the condition of the fill plug gasket. Do not replace the fill plug gasket unless damage (cracking) is found.





12. Fill the transfer case with 75W-85W GL4 gear oil.

Quantity: 270 cc (9-1/4 fl oz).

CAUTION:
Do not overfill the transfer case with oil. The correct level is 11 to 13 mm BELOW the level of the filler plug opening. Overfilling the transfer case can result in extensive power train damage. Failure to use the recommended viscosity and API rating gear oil can cause damage to transfer case components.





13. Reinstall the fill plug and torque the plug to 33 N-m (24 ft.lbs.).





14. Using new exhaust gaskets and nuts, reconnect the exhaust system. Torque the nuts to 50 N-m (37 ft.lbs.). Resecure the front exhaust pipe support.

15. If used, remove the wire supporting the exhaust pipe.





16. Clean the bottom of the transfer case with multi-purpose cleaner/degreaser. Mark the transfer case with a black permanent marker or black paint. This mark is necessary to provide future service technicians with a visual mark to indicate that this recall has been completed.

17. Drain the old transfer case of oil. Repackage the transfer case into the same box in which the replacement case came in. Affix a properly filled in return label to the box and store until return is requested by a material return request letter.

Note:
If an orange "GETRAG CORE RETURN LABEL" (MSSF026D00) is not available, photo-copy the label example shown in this bulletin, cut out as shown, and securely affix the copy on the box.