Transfer Case Modification
Note:Do not remove the front exhaust pipe or the propeller shaft for these procedures.
1. Reinstall the drain plug. Torque the drain plug to 33 N-m (24 ft.lbs.).
Note:
Do not replace the drain plug gasket unless damage (cracking) is found.
2. Remove the 2 nuts securing the front exhaust pipe to the rear catalytic converter. Remove the 2 nuts securing the front catalytic converter to the turbocharger outlet. Disconnect the front exhaust pipe support. Disconnect the front exhaust pipe and if necessary support the front exhaust pipe by using a piece of mechanic's wire. Discard the 2 exhaust gaskets and the 4 nuts.
3. Remove the 5 bolts securing the transfer case to the transaxle.
Note:
The upper 5th mounting bolt is hidden from view.
4. Separate the transfer case from the transaxle. If necessary, use a plastic hammer to tap the transfer case loose.
CAUTION:
When removing the transfer case (next step) do not allow the propeller shaft to hang. Allowing the propeller shaft to hang could damage the shaft's joint or bend the propeller shaft. Have an assistant help If necessary.
5. Remove the transfer case from the transaxle by tilting the case downward. Disconnect the transfer case from the propeller shaft.
6. Use mechanic's wire to support the propeller shaft.
7. Using a shop towel, remove any residue and dirt from the input shaft.
8. Remove the 6 bolts securing the transfer cover.
9. Remove the transfer cover by tapping it with a plastic hammer or (gently) tap on the input shaft.
CAUTION:
When removing the transfer case cover, do not damage the sealing (mating) surfaces by using a tool to pry the cover off. Do not damage the input shaft. Input shaft damage can occur if the gear is allowed to fall out of the transfer case or by striking the shaft with a metal hammer.
10. Remove the input shaft from the transfer case. Carefully inspect the gear tooth faces. If pitting or other damage is discovered, replace the transfer case assembly.
11. Remove the transfer case bracket from the case.
12. Remove the breather plug from the case.
13. Remove the 5 bolts securing the extension housing to the case. Separate the extension housing from the transfer case.
CAUTION:
Do not damage the sealing (mating) surfaces of the transfer case and the extension housing by prying the pieces apart with a screwdriver. Scratches or gouges will not only affect sealing quality but also affect gear mating when reassembled.
14. Apply an after market sealant remover to the old sealant on the 4 sealing surfaces (both sides of the transfer case, extension housing, and transfer case side cover). Using a plastic scraper, remove the old sealant. Remove any remaining sealant particles by using a plastic bristle brush.
CAUTION:
Do not use a metal scraper or wire brush to remove the old sealant. To protect the seal from dirt and sealant residue, place a shop towel inside the transfer case covering the seal.
15. Remove any sealant residue from the sealing surfaces by using multi-purpose cleaner or equivalent, a shop towel, and/or compressed air.
Note:
Thoroughly clean the groove in the transfer case side cover.
16. Clean the bolt threads (5 extension housing and 6 side cover).
CAUTION:
If ANY oil is squeezed out from the extension housing to transfer case sealing surface (including the bolt holes) during steps 17 through 33, the re-sealing process MUST BE REPEATED restarting at the appropriate step as indicated.
17. Clean the bolt holes (5 extension housing and 6 side cover) of sealant residue by using a thread chaser tap (8 mm x 1.25 mm).
Note:
A thread chaser tap is different from a standard thread cutting tap. Chasers just clean the threads. Tool suppliers can provide additional information if necessary.
Remove any sealant residue and/or oil from the bolt holes and the inside of the case by using multi-purpose cleaner and compressed air.
Thoroughly clean the inside of the case.
CAUTION:
Remove all oil and sealant residue from the bolt holes.
18. Use a soft brush and/or compressed air to clean the output shaft gear face.
19. Apply a thin coating of gear oil to the new O-ring.
20. Carefully install the O-ring onto the extension housing.
CAUTION:
Do not damage or nick the O-ring. A sharp tool or contact with the gear face can cause damage to the O-ring during installation. When installed, there should be NO twists in the O-ring. Do not over-stretch the O-ring during installation.
CAUTION:
Make certain the O-ring is completely seated in the corner. DO NOT APPLY ANY SEALANT TO THE O-RING OR THE TRANSFER CASE TO EXTENSION HOUSING SEALING SURFACE!
21. Carefully install the extension housing into the transfer case. If necessary, use a plastic hammer to gently tap the housing into place.
CAUTION:
When installing the extension housing, use extreme care and gently/gradually insert the housing into the case. Do not damage or nick the O-ring.
22. Apply a large amount of thread locking compound to the 5 extension housing bolts. Tighten the bolts evenly to "seat" the extension housing into the case. Use a torque wrench to torque the bolts to 25 N-M (18 ft.lbs.).
CAUTION:
If ANY oil is squeezed out from the extension housing to transfer case sealing surface, the re-sealing process MUST BE REPEATED restarting at step 17.
23. Remove any old adhesive from the breather plug "stud" and transfer case.
24. Apply weatherstrip adhesive to the breather plug flange and "stud".
CAUTION:
Do not cover the "breathing" opening of the plug with adhesive.
25. Install the breather plug into the extension housing.
26. Apply thread locking compound to the transfer case bracket mounting bolt. Install the bracket to the case. Using a torque wrench, torque the bolt to 25 N-m (18 ft.lbs.).
27. Lightly coat the input seal and the bearing race with the recommended transfer case oil (75W-85W GL4).
28. Use a soft brush and or compressed air to clean the input gear face. Install the input gear into the transfer case.
CAUTION:
Do not damage the input gear seal when installing the gear into the case. Insert the gear vertically.
29. Inspect the input gear seal for damage. Damage will typically look like a tear, fold, and/or a sliver of rubber hanging from the seal. Replace the seal (at dealer expense - this part cannot be claimed) if damaged.
30. Apply a small amount of the recommended gear oil on the side cover outer bearing race.
31. Apply a large amount of Mitsubishi Genuine Sealant (MD997740) to the transfer case side cover. Make certain the groove is filled with sealant.
Note:
Sealant must be applied as a continuous bead with no air pockets in the groove.
32. Install the transfer case side cover onto the transfer case. Use a plastic hammer if necessary.
Note:
Align the bolt holes before tapping cover into place.
33. Apply a large amount of thread locking compound to the 6 transfer case side cover bolts. Tighten the bolts evenly to "seat" the side cover onto the case. Use a torque wrench to torque the bolts to 25 N-m (18 ft.lbs.).
CAUTION:
If ANY oil is squeezed out from the side cover to transfer case sealing surface (including the bolt holes), the re-sealing process MUST BE REPEATED restarting at step 23.
34. Apply a coating of the recommended gear oil to the output seal.
Apply grease to the splines of the transfer case output shaft.
35. Apply grease to the splines of the transaxle output shaft.
36. If necessary, enlist the help of an assistant for this step. Loosen (do not remove) the wire supporting 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.
37. 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.
38. 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.
39. Reinstall the fill plug and torque the plug to 33 N-m (24 ft.lbs.).
40. 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.
41. 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.
42. If used, remove the wire supporting the exhaust pipe.
END OF PROCEDURE