- Lubricate the O-rings (2, 3) with petroleum jelly.
- Install the intermediate shaft O-ring seals (2).
- Install the half shaft retainer (1).
- Install the transfer case O-ring seal (3).
Note: Oxidation must be removed from the transmission torque converter housing differential bore surface before installation of the transfer case. A clean bore will prevent oxidation build up from scuffing or cutting the O-ring seal
upon transfer case installation, resulting in a leak.
- Carefully insert a clean soft cloth into the transmission torque converter housing differential bore to prevent debris from entering the transmission.
- Clean the oxidation from the transmission torque converter housing differential bore surface using steel wool or crocus cloth.
- Carefully remove any debris and the cloth from the transmission torque converter housing differential bore.
Note: Use guide pins to aid in alignment and installation of the transfer case to the transmission. Failure to use guide pins may result in cutting the transfer case O-ring seal during installation of the transfer case causing a fluid
leak.
- Fabricate 2 guide pins by cutting the heads off of 2 bolts M12x1.75x75. chamfer and remove burrs from the cut end of the bolt.
- Hand thread the guide pins (1) into the transmission upper and lower transfer case mounting bolt holes.
- Install the transfer case (1) to the transmission.
- Remove the guide pins (2).
Caution: Refer to Fastener Caution in the Preface section.
- Install the transfer case to transmission bolts (1).
Tighten
Tighten the bolts to 50 N·m (37 lb ft).
- Install the engine rear mount bracket. Refer to
Engine Rear Mount Replacement.
- Remove the jackstand from under the transaxle.
- Install the exhaust flexible pipe. Refer to
Exhaust Flexible Pipe Replacement.
- Install the right wheel drive shaft. Refer to
Front Wheel Drive Shaft Replacement.
- Install the propeller shaft. Refer to
Propeller Shaft Replacement.
- Fill the transfer case with fluid. Refer to
Transfer Case Fluid Replacement.
- Lower the vehicle.