Dismantling
1. Drain the oil from the transfer case.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
2. Remove the right drive shaft seal.
TRANSFER BOX, REPAIR WORKS, Right drive shaft oil seal.
3. Turn away a nut of fastening of a heat-shielding screen to a distributing box.
4. Turn away a nut of fastening of a heat-shielding screen to a case of a shaft of a drive of the back bridge.
5. Turn away 2 bolts of fastening of a heat-shielding screen and remove the screen.
6. Remove the lower cross member of the engine mount.
ENGINE - Td4, Intake and exhaust camshafts, engine mount lower cross member.
7. Turn out 3 bolts of fastening of an arm of a distributing box to the pallet.
8. Turn out 2 bolts of fastening of an arm to a distributing box and remove an arm.
9. Turn away 3 bolts of fastening of the top arm of a distributing box to the engine.
10. Turn out 2 bolts of fastening of the top arm to a distributing box and remove an arm.
11. Turn away 8 bolts of fastening of a back cover to a case of a distributing box.
12. Remove the back cover.
Installation
1. Remove the remnants of the old sealant from the mating surfaces of the cover and transfer case housing.
2. Apply a narrow bead of STC 4600 sealant to the mating surface of the rear cover.
3. Install the rear cover on the transfer box housing, tighten the bolts sequentially to 30 Nm.
4. Install the transfer box bracket and pull the mating surfaces together.
5. Completely tighten the transfer case bracket bolts in the following sequence:
- M10 bolts for fastening the brackets to the transfer case with a torque of 50 Nm
- Three bolts securing the bracket to the cylinder block with a torque of 25 Nm
- Three bolts securing the bracket to the pallet with a torque of 45 Nm.
6. Reinstall the engine mount lower cross member.
ENGINE - Td4, Intake and exhaust camshafts, engine mount lower cross member.
7. Install the heat shield.
8. Fit the nut securing the heat shield to the transfer case and tighten it to 45 Nm.
9. Screw in the bolts securing the heat shield to the transfer case bracket and tighten them to 9 Nm.
10. Fit the nut securing the heat shield to the rear axle drive shaft housing and tighten it to 30 Nm.
11. Establish an epiploon of the right power shaft.
TRANSFER BOX, REPAIR WORKS, Right drive shaft oil seal.
12. Fill oil into the transfer case housing to the required level.
TRANSFER BOX, ADJUSTMENTS, Changing the transmission oil in the transfer case: except for the North American market.
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