Transfer Case Replacement

Note:
Do not remove the front exhaust pipe or the propeller shaft for these procedures.

1. Reinstall the drain plug.

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 assist.

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.