Removal and Replacement

TRANSFER UNIT

Components:

Components:

REMOVAL
1. DISCONNECT CABLE FROM NEGATIVE BATTERY TERMINAL

CAUTION: Wait at least 90 seconds after disconnecting the cable from the negative (-) battery terminal to prevent airbag and seat belt pretensioner activation.

2. RAISE VEHICLE

NOTICE: Make sure that the vehicle is securely supported.





3. REMOVE TRANSFER CASE PROTECTOR
a. Remove the 3 bolts and transfer case protector.
Torque: 28 Nm (290 kgf-cm, 21 ft. lbs.)
4. DRAIN TRANSFER OIL
a. Drain transfer oil.
5. REMOVE FRONT PROPELLER SHAFT ASSEMBLY
a. Remove the front propeller shaft.
6. REMOVE REAR PROPELLER SHAFT ASSEMBLY
a. Remove the rear propeller shaft assembly.





7. REMOVE TRANSFER SHIFT LEVER ROD ASSEMBLY
a. Remove the clip, plate washer, wave washer and bushing, and disconnect the transfer shift lever rod.
8. REMOVE BODY GROUND WIRE SUB-ASSEMBLY
a. Remove the bolt and disconnect the body ground wire from the transfer.





9. REMOVE CROSSMEMBER
a. Support the transmission, as shown in the illustration.

NOTICE: Use a wooden block so not to damage the transmission oil pan.

b. Remove the 8 bolts, 2 nuts and crossmember.
Torque:
50 Nm (510 kgf-cm, 37 ft. lbs.) for bolt
74 Nm (750 kgf-cm, 54 ft. lbs.) for nut





10. DISCONNECT BREATHER HOSE

HINT: At the time of installation, assemble the clip to the position shown in the illustration.

11. DISCONNECT VEHICLE SPEED SENSOR CONNECTOR
12. DISCONNECT TRANSFER INDICATOR SWITCH CONNECTOR
13. DISCONNECT MOTOR ACTUATOR CONNECTOR
14. JACK UP TRANSFER ASSEMBLY
a. Using a transmission jack, support the transfer.





15. REMOVE TRANSFER ASSEMBLY
a. Disconnect the wire harness from the transfer.
b. Remove the 6 transfer adaptor rear mounting bolts.
Torque: 69 Nm (700 kgf-cm, 51 ft. lbs.)
c. Pull out the transfer down and toward the rear.

INSTALLATION
Installation is in reverse order of removal.

HINT:
^ Apply MP grease to the transfer adapter oil seal.
^ After install, do the road test.