Tools Required

Important: Transmission oil circulates between the transmission and the transfer case. In situations where transmission failures circulate debris into the transfer case, the transfer case must be disassembled, cleaned, and inspected for damage. Refer to Internal Components Cleaning and Inspection in Transfer Case - Steyr Unit Repair.

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.



3. Remove the drain plug (1) drain the transfer case oil.



4. Remove the drain plug (1) in order to drain the transmission fluid.
5. Disconnect the vehicle speed sensor electrical connector.
6. Remove the transfer case brace. Refer to Support Brace Replacement .



7. Remove the vent tube clamp (1).
8. Separate the vent tube from the vent tube bracket.
9. Remove the vent tube from the transfer case.

Notice: Removal and installation of the transfer case while the transmission is in vehicle may cause improper positioning of the park gear thrust bearing. If the transfer case fasteners are tightened while the park gear thrust bearing is out of position, the park gear thrust bearing, transmission, and/or the transfer case will be damaged.

10. Remove the transfer case with the transaxle. Refer to Transmission Replacement in Automatic Transaxle - 4T65-E.
11. Install the transaxle to the transmission support fixture. Refer to Transmission Support Fixture Assemble in Automatic Transaxle - 4T65-E Unit Repair.



12. Remove and discard the left output shaft retaining ring (1).



13. Rotate the transaxle 90 degrees so that the transmission side cover is facing down.



14. Rotate the transaxle 90 degrees.
15. Remove the transfer case side brace bolts (1 through 5), and the transfer case side brace (6).



16. Remove the transfer case bolts (1 through 5).




Caution: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

Notice: During removal of the transfer case/output shaft, do not use excessive force or damage to the bushings may occur.

17. Remove the transfer case (1) with the output shaft (2) from the transaxle (3).



18. Install the transfer case assembly to the J 44755 .

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

19. Install the retaining bolts.

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




20. Attach the J 6125-1B to the J 44467 .
21. Install the J 44467 into the snap ring groove on the output shaft (510) and tighten securely.
22. Use the J 6125-1B and the J 44467 to remove the output shaft.
23. Remove the output shaft from the transfer case. Perform the following steps.



24. Remove the transfer case seal (1) from the transfer case (2).



25. Remove the oil dam from the transaxle.



26. If you are replacing the transfer case, remove the transfer case lower brace bolts (903) and the lower brace (906).

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 in Automatic Transmission - 4T65-E Unit Repair.

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.



2. Install a new seal transfer case seal (1).




Important: The oil dam (901) must be installed with the notch aligned to the oil passage in the transaxle case (1).

3. Install the oil dam (901) to the transaxle.



4. Rotate the transaxle 90 degrees.

Caution: This component weighs approximately 60 lbs. Personal injury may result if you lift the component improperly.

5. Install the transfer case to the transaxle.




Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

6. Install the transfer case bolts (1) and (2).

Tighten

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

Tighten

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

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




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

Tighten
Tighten transfer case side brace bolts to 32N·m (24 lb ft).




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

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




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

Tighten
Tighten the bolts to 32N·m (24 lb ft).

13. Install the output shaft to the transmission. Refer to Output Shaft Assemble in Automatic Transaxle - 4T65-E Unit Repair.



14. Install a new output shaft retaining ring  (1).
15. Install the transaxle with the transfer case. Refer to Transmission Replacement in Automatic Transaxle - 4T65-E.



16. Install the vent hose (2) and the clamp (1) to the transfer case.
17. Install the vehicle speed sensor electrical connector.
18. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
19. Install the transfer case drain plug and fill the transfer case with the specified synthetic gear oil. Refer to Transfer Case Fluid Replacement .



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

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

21. Install the transfer case lower brace. Refer to Support Brace Replacement .
22. Lower the vehicle.
23. Inspect and adjust the transmission fluid level. Refer to Transmission Fluid Check in Automatic Transaxle - 4T65-E.