Contents: Dismantling ⇩ Installation ⇩
Dismantling
1. Drain the oil from the transfer case.
TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.
TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: North American market countries.
2. North American models: Remove the right catalytic converter.
POISONING SYSTEM, Positive crankcase ventilation valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
3. Remove the right drive shaft oil seal.
TRANSFER CASE, REPAIR WORK, Right drive shaft seal.
The material was taken from the specified website: www.LRman.ru
4. Except for North American models: Remove the nut securing the exhaust manifold heat shield to the transfer case.
5. Except for North American models: Remove the nut securing the exhaust manifold heat shield to the rear axle drive shaft housing.
6. Except for North American models: Remove the 2 heat shield mounting bolts and remove the shield.
7. Remove the lower engine mount cross member.
ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Lower engine mounting cross member.
8. Remove the 3 bolts securing the transfer case bracket to the pan.
9. Unscrew the 2 bolts securing the transfer case bracket to the front engine plate.
10. Unscrew the 5 bolts securing the bracket to the transfer case and remove the bracket.
11. Unscrew the 8 bolts securing the rear cover to the transfer case housing.
12. Remove the back cover.
Installation
1. Remove any remaining old sealant from the mating surfaces of the transfer case cover and housing.
2. Apply a narrow bead of STC 4600 sealant to the mating surface of the rear cover.
3. Install the rear cover onto the transfer case housing, tighten the bolts sequentially to a torque of 30 Nm.
4. Install the transfer case bracket and tighten the mating surfaces together.
5. Finally tighten all bolts in the following sequence:
- Five bolts for fastening the bracket to the transfer case with a torque of 50 Nm
- Two bolts securing the bracket to the front engine bracket with a torque of 50 Nm
- Three bolts for fastening the bracket to the pan with a torque of 88 Nm.
6. Reinstall the lower engine mount cross member.
ENGINE KV6 - MODIFICATION K, Camshafts of the left cylinder head, Lower engine mounting cross member.
7. Except for North American models: Install the heat shield.
8. Except for North American models: Install the heat shield-to-transfer case nut and tighten to 45 Nm.
9. Except for North American models: Install the heat shield to transfer case bracket bolts and tighten to 9 Nm.
10. Except for North American models: Install the heat shield to rear drive shaft housing nut and tighten to 25 Nm.
11. Install the right drive shaft oil seal.
TRANSFER CASE, REPAIR WORK, Right drive shaft seal.
12. Fill the transfer case with oil to the required level.
TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for North American market countries.
TRANSFER CASE, ADJUSTMENTS, Changing the transmission oil in the transfer case: North American market countries.
13. North American Market Models: Install the right catalytic converter.
POISONING SYSTEM, Positive crankcase ventilation valve: Td4 engine, Right bank catalytic converter: KV6 engine, North American market countries.
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