Transfer Case Assemble

Transfer Case Assemble

Install the intermediate shaft seal (3), to the rear extension housing using the DT-49953 installer (2) with DT-305-1/KM-305-1 remover/installer (1).

Input Shaft Bearing Retainer Rear Seal Installation

Special Tools

•	DT-305-1/KM-305-1 Remover/Installer

•	DT-49952 Seal Installer

For equivalent regional tools, refer to Special Tools

1.	Clean the transfer case rear extension housing threaded bolt holes. A thread repair tool may be used to clean the threads of old threadlocking material.

2.	Spray thread cleaner into the holes. Refer to Adhesives, Fluids, Lubricants, and Sealers .

3.	Warning Wear safety glasses when using compressed air in order to prevent eye injury. Clean the transfer case housing and rear extension housing bolt holes with compressed air.

4.	Note Install the NEW seal with the notched surface of the seal facing away from the installer tool. Install the NEW input shaft rear seal (1) to the rear extension housing using the DT-49952 installer (2) and DT-305-1/KM-305-1 remover/installer (3).

Idler Gear Shaft Rear Seal Installation

Install a NEW idler gear shaft rear seal (1) to the rear extension housing. - RPO MXE

Idler Gear Shaft Front Seal Installation

Install a NEW transfer case idler gear shaft front seal (1) to transfer case. - RPO MXE

Input Shaft Bearing Retainer Front Seals Installation

Special Tools

•	DT-305-1/KM-305-1 Remover/Installer

•	DT-49952 Installer

For equivalent regional tools, refer to Special Tools .

1.	Note Install the NEW seal with the notched surface of the seal facing the installer tool. Install the front input shaft (inner) seal (1) to the transfer case using the DT-49952 installer (2) and DT-305-1/KM-305-1 remover/installer (3).

2.	Note Install the NEW seal with the notched surface of the seal facing the installer tool. Install the front input shaft (outer) seal (1) to the transfer case using the DT-49952 installer (2) and DT-305-1/KM-305-1 remover/installer (3).

Input Shaft and Idler Gear Installation

Install input shaft (1) and idler gear (2).

Rear Extension Housing Installation - RPO MXE

1.	Install the idler gear shaft (1) to the rear extension housing - RPO MXE.

2.	Install a NEW rear extension housing-to-transfer case seal (1).

3.	Install the rear extension housing (1) and idler gear shaft to the transfer case housing. Position the idler gear shaft into the center opening of the idler gear.

4.	Refer to Fastener Caution . Apply threadlock to the threads on the NEW bolts for the transfer case to the extension housing (1). See Adhesives, Fluids, Lubricants, and Sealers .

5.	Install the NEW transfer case-to-rear extension housing bolts (1).

5.1.

Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft) .

5.2.

Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.

Rear Extension Housing Installation - RPO MH4

1.	Install a NEW rear extension housing-to-transfer case seal (1).

2.	Install the rear extension housing onto the transfer case housing.

3.	Refer to Fastener Caution . Apply threadlock to the threads on the NEW bolts for the transfer case to the extension housing. See Adhesives, Fluids, Lubricants, and Sealers .

4.	Install the NEW transfer case-to-rear extension housing bolts (1).

4.1.

Tighten the 10 transfer case-to-rear extension housing bolts (1) a first pass to 25 Nm (18 lb ft) .

4.2.

Tighten the 10 transfer case-to-rear extension housing bolts (1) a second pass 130 degrees.

Rear Output Shaft Seal Installation

Special Tools

•	DT-305-1/KM-305-1 Remover/Installer

•	DT-49954-A Seal Installer

For equivalent regional special tools, refer to Special Tools .



Install the rear output shaft seal (3), using the DT-49954-A installer (2) and DT-305-1/KM-305-1 remover/installer (1).

Front Wheel Drive Intermediate Shaft Bearing Installation

Special Tools

DT-48076 Bearing Installer

For equivalent regional tools, refer to Special Tools .

1.	Press on the intermediate shaft bearing (2) onto the intermediate shaft (3), using DT-48076 Bearing installer (1) and a hydraulic press.

2.	Install the transfer case intermediate shaft bearing retaining ring (2) to intermediate shaft (1), using suitable pliers.

Front Wheel Drive Intermediate Shaft Installation

Special Tools

•	DT-113-2-A Holder

•	DT-622-A Transmission Bracket

•	DT-48076 Bearing Installer

•	DT-49104 Protective Collar

For equivalent regional tools, refer to Special Tools .

1.	Install the DT-49104 protective collar (1) to the intermediate shaft (2), and tap in the intermediate shaft using the DT-48076 installer (3) and a rubber mallet.

2.	Remove the DT-49104 protective collar (1).

3.	Apply grease to the intermediate shaft output splines (1). See Adhesives, Fluids, Lubricants, and Sealers .

4.	Refer to Fastener Caution . Install the transfer case intermediate shaft retaining ring (1), using suitable snap ring pliers.

5.	Fit the NEW dirt deflector/grease seal assembly (1) using DT-48076 Bearing installer.

Locating Bushing Installation

Install the transfer case locating bushing (1) as required using a rubber mallet-RPO MXE.

Transfer Case-to-Transmission Seal Installation

Install the NEW transfer case-to-transmission seal (1).

Transfer Case Vent Installation

1.	Apply sealant to the threads of the vent hose connector. Refer to Adhesives, Fluids, Lubricants, and Sealers .

2.	Install the transaxle breather hose contact (1) and tighten to 25 Nm (18 lb ft) .

Oil Drain Plug Installation

Refer to Fastener Caution .

Install a NEW oil drain plug (1) and tighten to 40 Nm (30 lb ft) .

Oil Fill Plug Installation

1.	Install a NEW transfer case oil fill plug (1).

2.	Once the transfer case has been filled with oil, tighten the oil fill plug to 40 Nm (30 lb ft) .

3.	Remove the transfer case (3) from DT-622-A bracket (2) and DT-113-2-A holder (1).