| : | Apr 27, 2005 |
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| . | Disconnect the battery ground cable. |
| . |
Raise and support the vehicle. |
| . | Drain the transfer case fluid. |
| . | Remove the transfer case. |
| . | With assistance, secure the transfer case with
its transmission mating face down on a flat surface.
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| . |
Remove the shift motor.
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| . |
Remove 17 Torx bolts securing the transfer casings.
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| . |
Remove the rear half of the transfer case.
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| . | Remove the differential module.
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| . |
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Remove the clutch, chain and sprocket. ![]() |
| . | Remove the rear output flange.
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| . |
Remove the output flange seal. ![]() |
| . | Remove the output flange bearing.
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| . | Release the front half of the transfer case from
the flat surface.
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| . | Remove the sealant from the transfer case mating faces. |
| . | Clean the magnetic filter. |
| . |
Using the special tool, install the output flange bearing.
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| . | Using the special tool, install a new oil seal.
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| . |
Using the special tool and with assistance, install the drive flange.
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| . | Secure the rear half of the transfer case with its rear face down on a flat surface. |
| . |
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Install the differential module.
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Install the clutch.
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| . |
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Install the chain and sprocket.
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| . | Apply a 2 mm bead of sealant to one surface of
the transfer case mating face, as shown.
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| . | Install the front half of the transfer case.
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| . | Tighten the remaining Torx bolts to 35 Nm (26 lb.ft). |
| . | Install the shift motor.
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| . | With assistance, release the transfer case from
the flat surface.
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| . | Install the transfer case. |
| . | Refill the transfer case with the recommended
fluid. |
| . | Connect the battery ground cable. |