Transfer Case

REMOVAL & INSTALLATION

1. Disconnect the negative battery cable.
2. Remove the transmission and transfer case assembly from the vehicle.
3. Remove the oil filler and oil drain plugs and washers.
4. Remove the selector plunger from the right side of the case.
5. Remove the selector spring and plunger or steel ball.
6. Extract the spring pin from the change shifter.
7. Remove the transfer case to transmission attaching nuts and separate the transfer case from the transmission. When removing the transfer-to-transmission case mounting bolts and nuts, note the position of the two cord fasteners. When the cases are pulled apart, remove the change shifter from the control shaft.

   Fig. 1: Transmission transfer case removal and installation — all transfer cases similar

   Fig. 2: Use the special tool (or a punch if the tool is not available) MD998245–01 to install the spring clip into the change shifter — all transfer cases similar

   Fig. 3: Install the spring clip so that the slit is facing the direction shown in the illustration — All transfer cases similar

   To install:

8. When reinstalling, carefully fit the transfer case to the transmission case with a new gasket between them. Apply 3M® ART Part No. 8001 or Part No. 8011, or equivalent to both sides of the gasket and affix it to the rear surface of the adapter. Make sure the end of the transmission output shaft is lightly greased to ease the fit to the transfer case. As the two cases are slid together, install the change shifter to the control shaft.
9. Connect the two units and install the case bolts, making sure to install the two cord fasteners. Tighten the bolts to 22–30 ft. lbs (30–42 Nm).
10. Install the selector spring and plunger or steel ball.
11. Carefully install the spring pin holding the change shifter to the control shaft, using the Mitsubishi tool MD998245–01. Drive the the spring pin in with the slit in the spring pin parallel to the shaft center of the shift rail, so that the dimensions are shown in the illustration.
12. Reinstall the transmission/transfer case as a unit.