Transfer Case Assemble
Transfer Case AssembleFront Wheel Drive Intermediate Shaft Seal Installation
Special Tools
- DT-305 Remover/Installer
- DT-49953 Seal Installer
For equivalent regional tools, refer to Special Tools.
Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 installer (2) with DT-305 remover/installer (1).
Input Shaft Bearing Retainer Rear Seal Installation
Special Tools
- DT-305 Remover/Installer
- DT-49952 Seal Installer
For equivalent regional tools, refer to Special Tools.
1. Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to clean the threads of old thread locking material.
2. Spray thread cleaner into the holes.
3. Warning
Wear safety glasses when using compressed air in order to prevent eye injury.
Clean the transfer case housing and rear extension housing bolt holes with compressed air.
4. Note
Install the NEW seal with the notched surface of the seal facing away from the installer tool.
Install the NEW input shaft rear seal (1) to the rear extension housing using the DT-49952 installer (2) and DT-305 remover/installer (3).
Idler Gear Shaft Rear Seal Installation
Install a NEW idler gear shaft rear seal (1) to the rear extension housing. - RPO MXE
Idler Gear Shaft Front Seal Installation
Install a NEW transfer case idler gear shaft front seal (1) to transfer case. - RPO MXE
Input Shaft Bearing Retainer Front Seals Installation
Special Tools
- DT-305 Remover/Installer
- DT-49952 Installer
For equivalent regional tools, refer to Special Tools.
1. Note
Install the NEW seal with the notched surface of the seal facing the installer tool.
Install the input shaft front (inner) seal (1), to the transfer case using the DT-49952 installer (2) and DT-305 remover/installer (3).
2. Note
Install the NEW seal with the notched surface of the seal facing the installer tool.
Install the input shaft front (outer) seal (1), to the transfer case using the DT-49952 installer (2) and DT-305 remover/installer (3).
Input Shaft and Idler Gear Installation
Install input shaft (1) and idler gear (2).
Rear Extension Housing Installation - RPO MXE
1. Install the idler gear shaft (1) to the rear extension housing - RPO MXE.
2. Install a NEW rear extension housing-to-transfer case seal (1).
3. Install the rear extension housing (1) and idler gear shaft to the transfer case housing. Position the idler gear shaft into the center opening of the idler gear.
4. Refer to Fastener Caution.
Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts (1).
5. Install the NEW transfer case-to-rear extension housing bolts (1).
5.1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft).
5.2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.
Rear Extension Housing Installation - RPO MH4
1. Install a NEW rear extension housing-to-transfer case seal (1).
2. Install the rear extension housing onto the transfer case housing.
3. Refer to Fastener Caution.
Apply threadlock to the threads of the NEW transfer case-to-rear extension housing bolts.
4. Install the NEW transfer case-to-rear extension housing bolts (1).
4.1. Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft).
4.2. Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.
Rear Output Shaft Seal Installation
Special Tools
- DT-305 Remover/Installer
- DT-49954-A Seal Installer
For equivalent regional special tools, refer to Special Tools.
Install the rear output shaft seal (3), using the DT-49954-A installer (2) and DT-305 remover/installer (1).
Front Wheel Drive Intermediate Shaft Bearing Installation
Special Tools
DT-49408 Ring, Pinion Bearing
For equivalent regional tools, refer to Special Tools.
1. Press on the intermediate shaft bearing (2) onto the intermediate shaft (3), using DT-49408 ring (1) and a hydraulic press.
2. Install the transfer case intermediate shaft bearing retaining ring (2) to intermediate shaft (1), using suitable pliers.
Front Wheel Drive Intermediate Shaft Installation
Special Tools
- DT-113-2-A Holder
- DT-305 Remover/Installer
- DT-622-A Transmission Bracket
- DT-48076 Bearing Installer
- DT-49104 Protective Collar
For equivalent regional tools, refer to Special Tools.
1. Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft using the DT-48076 installer (3) with DT-305 remover/installer (4) and a rubber mallet.
2. Remove the DT-49104 protective collar (1).
3. Apply grease to the output splines (1) of the intermediate shaft.
4. Refer to Fastener Caution.
Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.
5. Install the NEW shaft dirt deflector and grease seal assembly (1).
Locating Bushing Installation
Install the transfer case locating bushing (1) as required using a rubber mallet-RPO MXE.
Transfer Case-to-Transmission Seal Installation
Install the NEW transfer case-to-transmission seal (1).
Transfer Case Vent Installation
1. Apply sealant to the threads of the vent hose connector.
2. Install the transaxle breather hose contact (1) and tighten to 25 Nm (18 lb ft).
Oil Drain Plug Installation
Refer to Fastener Caution.
Install a NEW oil drain plug (1) and tighten to 40 Nm (30 lb ft).
Oil Fill Plug Installation
1. Install a NEW transfer case oil fill plug (1).
2. Once the transfer case has been filled with oil, tighten the oil fill plug to 40 Nm (30 lb ft).
3. Remove the transfer case (3) from DT-622-A bracket (2) and DT-113-2-A holder (1).
