Installation Procedure

Important:  If you are replacing anything other than gaskets or seals, the transmission to transfer case end play check must be performed. Refer to TRANSMISSION-TO-TRANSFER CASE END PLAY CHECK

1. If you are replacing the transfer case, install the transfer case lower brace (906) and the lower brace bolts (903). Do not tighten the bolts.
   Fig 1: Installing Transfer Case Lower Brace & Bolts

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2. Install a new seal transfer case seal (1).
   Fig 2: Installing Transfer Case & Seal

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3. Rotate the transaxle 90 degrees.
   CAUTION: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.
4. Install the transfer case to the transaxle.
   Fig 3: Installing Transfer Case

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   NOTE: Refer to FASTENER NOTICE .
5. Install the transfer case bolts (1) and (2).

   Tighten 

   1. 5.1. Tighten the bolts to 35 N.m (26 lb ft).
   2. 5.2. Use the J 36660-A  to rotate the bolts 160 degrees.
6. Install the transfer case bolt (3).

   Tighten 

   1. 6.1. Tighten the bolt to 35 N.m (26 lb ft).
   2. 6.2. Use the J 36660-A  to rotate the bolts 70 degrees.
7. Install the transfer case bolts (4) and (5).

   Tighten 

   Tighten the bolts to 40 N.m (30 lb ft).

   Fig 4: Installing Transfer Case & Bolts

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8. Install the transfer case side brace (905).
9. Install and tighten the transfer case side brace bolts in the order shown.

   Tighten 

   Tighten transfer case side brace bolts to 31 N.m(23 lb ft).

   Fig 5: Installing Transfer Case Side Brace & Bolts

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10. Install the transfer case lower brace to case bolt (1).

    Tighten 

    Tighten the bolt to 56N.m (42 lb ft).

    Fig 6: Installing Transfer Case Lower Brace To Case Bolt

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11. Tighten the transfer case lower brace to transfer case bolts (903).

    Tighten 

    Tighten the bolts to 31N.m (23 lb ft).

    Fig 7: Tightening Transfer Case Lower Brace To Transfer Case Bolts

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12. Install the output shaft to the transmission. Refer to OUTPUT SHAFT .
13. Install a new output shaft retaining ring (1).
14. Install the transaxle with the transfer case. Refer to TRANSMISSION REPLACEMENT (M15) or TRANSMISSION REPLACEMENT (M76) .
    Fig 8: Installing Left Output Shaft Retaining Ring

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15. Install the vent hose (2) and the clamp (1) to the transfer case.
16. Install the vehicle speed sensor electrical connector.
17. Install the propeller shaft. Refer to PROPELLER SHAFT REPLACEMENT .
18. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to Transfer Case Fluid Replacement .
    Fig 9: Installing Transfer Case & Components

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19. Install the drain plug (1) and gasket to the case.

    Tighten 

    Tighten the drain plug to 32 N.m (24 lb ft).

20. Install the transfer case lower brace. Refer to Support Brace Replacement .
21. Lower the vehicle.
22. Inspect and adjust the transmission fluid level. Refer to CHECKING FLUID LEVEL & CONDITION .
    Fig 10: Installing Drain Plug

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