Transfer Case Assembly Replacement LZ4

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement .
3. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side .



6. Remove the transfer case mounting bracket bolts (1).
7. Remove the transfer case mounting bracket (2).



8. Remove the transfer case mounting bracket bolts (1, 3) and stud (2).
9. Remove the transfer case mounting bracket (4).
10. Support the transaxle with a jackstand.
11. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear .



12. Remove the bolts (1) securing the transfer case to the transaxle.
13. Remove the transfer case (2) from the transaxle.



14. If replacing the transfer case, complete the following steps.

•	Remove the transfer case heat shield bolts (1).

•	Remove the transfer case heat shield (2).

1. If the transfer case heat shield was previously removed, complete the following steps.

•	Install the transfer case heat shield (2).

•	Install the transfer case heat shield bolts (1).

Notice: Refer to Fastener Notice in the Preface section.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




2. Install the transfer case (2) from the transaxle.
3. Install the bolts (1) securing the transfer case to the transaxle.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

4. Install the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear .
5. Remove the jackstand supporting the transaxle.

Important: Tighten bolts in specified sequential order.




6. Install the transfer case mounting bracket (4).
7. Install the transfer case mounting bracket bolts (1) and stud (2).

Tighten
Tighten the bolts and stud in specified sequential order to 50 N·m (37 lb ft).

8. Install the transfer case mounting bracket bolt (3).

Tighten
Tighten the bolts in specified sequential order to 23 N·m (17 lb ft).




9. Install the transfer case mounting bracket (2).
10. Install the transfer case mounting bracket bolts (1).

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

11. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side .
12. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
13. Install the propeller shaft. Refer to Propeller Shaft Replacement .
14. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
15. Lower the vehicle.

Transfer Case Assembly Replacement LY7

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Drain the transfer case fluid. Refer to Transfer Case Fluid Replacement .
3. Remove the propeller shaft. Refer to Propeller Shaft Replacement .
4. Remove the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
5. Remove both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side .



6. Remove the transfer case mounting bracket bolts (1, 2, 4).
7. Remove the transfer case mounting bracket (3).
8. Support the transaxle with a jackstand.
9. Remove the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear .



10. Remove the bolts (1) securing the transfer case to the transaxle.
11. Remove the transfer case (2) from the transaxle.



12. If replacing the transfer case, complete the following steps.

•	Remove the transfer case heat shield bolts (1).

•	Remove the transfer case heat shield (2).

1. If the transfer case heat shield was previously removed, complete the following steps.

•	Install the transfer case heat shield (2).

•	Install the transfer case heat shield bolts (1).

Notice: Refer to Fastener Notice in the Preface section.

Tighten
Tighten the bolts to 10 N·m (89 lb in).




2. Install the transfer case (2) from the transaxle.
3. Install the bolts (1) securing the transfer case to the transaxle.

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

4. Install the rear transmission mount and bracket. Refer to Transmission Mount Bracket Replacement - Rear .
5. Remove the jackstand supporting the transaxle.

Important: Tighten bolts in specified sequential order.




6. Install the transfer case mounting bracket (3).
7. Install the transfer case mounting bracket bolts (1).

Tighten
Tighten the bolts to 23 N·m (17 lb ft).

8. Install the transfer case mounting bracket bolt (4).

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

9. Install the transfer case mounting bracket bolt (2).

Tighten
Tighten the bolts to 50 N·m (37 lb ft).

10. Install both catalytic converters. Refer to Catalytic Converter Replacement - Right Side and Catalytic Converter Replacement - Left Side .
11. Install the right wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement .
12. Install the propeller shaft. Refer to Propeller Shaft Replacement .
13. Fill the transfer case with fluid. Refer to Transfer Case Fluid Replacement .
14. Lower the vehicle.