Note: This is a general guide for all vehicles.
How to Replace an AWD Transfer Case
This guide requires the following supplies:
Always wear safety glasses when working on your vehicle. Wear other personal protective equipment (PPE) when necessary, for example latex gloves or closed toe shoes.
Use a jack to lift up the front of the vehicle. Every vehicle comes from the factory with a jack. To locate and properly use this jack see the owner's manual. The owner's manual will inform you what proper jacking locations should be used.
Locate the AWD transfer case.
Locate the oil fill plug on the AWD transfer case unit.
Remove the top oil fill plug.
Check for fluid at the top of the oil fill plug.
Remove the bottom drain plug and drain fluid into an oil drain pan.
Inspect the oil in the drain pan for metal flakes.
Locate the driveshaft. Mark a line at the slip yoke for correct re-alignment to the AWD transfer case unit.
Disconnect the driveshaft at the slip yoke, and lower the driveshaft from the AWD transfer case unit.
Locate the yoke on the rear driveshaft.
Remove the yoke from the driveshaft by loosening the nut and washer holding it in place.
Perform steps 9 through 12 for both the front and rear driveshafts.
Locate and disconnect any wiring harnesses connected to the AWD transfer case unit.
Locate and disconnect the speedometer driven gear on the AWD transfer case unit.
Locate and disconnect any linkages at the AWD transfer case unit shift lever.
Locate and disconnect the vent hose on the AWD transfer case unit.
Place the transmission floor jack under AWD transfer case unit for removal.
Remove the bolts holding the AWD transfer case unit to the transmission adapter.
Remove the AWD transfer case unit from the vehicle for inspection.
Place a new gasket between the AWD transfer case unit and the transmission adapter
Place the transmission floor jack under the AWD transfer case unit to install.
Install the new or rebuilt unit.
Install the bolts holding the AWD transfer case unit to the transmission adapter.
Remove the floor jack once the AWD transfer case unit is mounted.
Connect the heat shield or splash shield back into place.
Connect the vent hose and shifting linkage to the case.
Connect the speedometer driven gear and wiring harnesses to the case.
Connect the rear and front drive shafts to the output yokes and torque to manufacturer's specifications.
Install the fluid drain plug to the AWD transfer case unit.
Remove the fill plug and fill the AWD transfer case unit with the manufacturer's recommended fluid.
Re-install the AWD transfer case unit fill plug.
Torque the fill plug to the manufacturer's specifications.
Lower the vehicle and road test to verify the AWD transfer case unit repair.
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