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Transfer Case Removal/Installation

WARNING: This page is about a different car, the 2005 Mazda B4000. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, raise the vehicle on a hoist. See LIFTING .
  2. Remove the four bolts and the skid plate.
    Fig 1: Removing Four Bolts And Skid Plate - With Torque Specifications
    G03729955Courtesy of MAZDA MOTORS CORP.
  3. Remove the four bolts and the damper; See TRANSFER CASE DAMPER REMOVAL/INSTALLATION  .
  4. Disconnect the electronic shift motor harness connector and position aside.
    Fig 2: Disconnecting Electronic Shift Motor Harness Connector And Position Aside
    G03729956Courtesy of MAZDA MOTORS CORP.
  5. If disassembly is required, remove the drain plug and drain the transfer case. Replace the drain plug when fluid has drained.
    Fig 3: Replacing Drain Plug When Fluid Has Drained - With Torque Specifications
    G03729957Courtesy of MAZDA MOTORS CORP.
    CAUTION:
    • Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    CAUTION:
    • Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.
  6. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
    Fig 4: Disconnecting Front Driveshaft From Transfer Case And Position Driveshaft Aside
    G03729958Courtesy of MAZDA MOTORS CORP.
    1. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
    2. Remove and discard the bolts and washers.
    3. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
      CAUTION:
      • Index-mark the front flange on the rear driveshaft and the flange on the transfer case.
  7. Remove the rear propeller shaft. See PROPELLER SHAFT REAR (4X4) REMOVAL/INSTALLATION or see PROPELLER SHAFT REAR (4X2) REMOVAL/INSTALLATION .
    WARNING:
    • Secure the transfer case to the jack with safety straps.
  8. Position a high lift jack under the transfer case.
  9. Remove the five bolts retaining the transfer case to the extension housing.
    Fig 5: Sliding Transfer Case Rearward And Off Of The Transmission Output Shaft
    G03729959Courtesy of MAZDA MOTORS CORP.
  10. Slide the transfer case rearward and off of the transmission output shaft.
  11. Remove and discard the front extension housing gasket and clean the mating surfaces.
    Fig 6: Removing And Discard Front Extension Housing Gasket And Cleaning Mating Surfaces
    G03729960Courtesy of MAZDA MOTORS CORP.
  12. Install the new gasket on the front of the transfer case.
    Fig 7: Installing New Gasket On Front Of Transfer Case
    G03729961Courtesy of MAZDA MOTORS CORP.
    NOTE:
    • Install the front driveshaft with new bolts and washers and the rear driveshaft with new bolts. If new bolts are not available, coat the threads of the original bolts with threadlock and sealer.
    NOTE:
    • When installing the front driveshaft, always connect it to the axle first and then connect it to the transfer case.
    NOTE:
    • Align the index marks when installing the front and rear driveshafts.
  13. Install procedure in reverse order of removal.
    Fig 8: Tightening Torque Of Driveshafts
    G03729962Courtesy of MAZDA MOTORS CORP.
  14. Check and, if necessary, fill the transfer case with the specified type and quantity of fluid. See TRANSFER CASE FLUID  .
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