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.
2. Remove the right drive shaft oil seal.
TRANSFER CASE, REPAIR WORK, Right drive shaft seal.
3. Loosen the nut securing the heat shield to the transfer case.
4. Loosen the nut securing the heat shield to the rear axle drive shaft housing.
5. Unscrew the 2 heat shield mounting bolts and remove the shield.
6. Remove the lower engine mount cross member.
ENGINE - Td4, Inlet and outlet camshafts, Lower engine mount cross member.
7. Remove the 3 bolts securing the transfer case bracket to the pan.
8. Unscrew the 2 bolts securing the bracket to the transfer case and remove the bracket.
9. Unscrew the 3 bolts securing the upper bracket of the transfer case to the engine.
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10. Unscrew the 2 bolts securing the upper 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 the transfer case bracket bolts in the following sequence:
- M10 bolts for fastening brackets to the transfer case with a torque of 50 Nm
- Three bolts for fastening the bracket to the cylinder block with a torque of 25 Nm
- Three bolts for fastening the bracket to the pan with a torque of 45 Nm.
6. Reinstall the lower engine mount cross member.
ENGINE - Td4, Inlet and outlet camshafts, Lower engine mount cross member.
7. Install the heat shield.
8. Fit the heat shield mounting nut to the transfer case and tighten it to 45 Nm.
9. Screw in the heat shield mounting bolts to the transfer case bracket and tighten them to a torque of 9 Nm.
10. Fit the heat shield mounting nut to the rear axle drive shaft housing and tighten it to a torque of 30 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.
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