Transfer Case Installation

NOTE: Oil dam must be installed with oil passage notch aligned to passage in case. Incorrect alignment will cause oil flow stoppage and damage to transaxle.

Install case extension seal. See Figure. Line up notch to hole in case and install oil dam. See Figure.
Install transfer case lower brace. See Figure. Install and hand tighten transfer case lower brace bolts. Rotate transaxle so oil pan is facing floor. Install transfer case assembly onto transaxle. See Fig 1.
Install 5 transfer case-to-transaxle bolts. See Figure. Torque bolts in sequence. Tighten transfer case bolts No. 1 and 2 in 2 passes; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 160 degrees. Tighten transfer case bolt No. 3; 1st pass 26 ft. lbs. (35 N.m), and 2nd pass an additional 70 degrees. Tighten transfer case bolts No. 4 and 5 to 30 ft. lbs. (40 N.m).
Install transfer case side brace to case and hand tighten bolts. Tighten bolts to 23 ft. lbs. (31 N.m) in numerical sequence (1, 2, 3, 4, 5). See Figure. Install transfer case lower brace-to-transaxle bolt and tighten to 42 ft. lbs. (56 N.m) See Figure. Tighten transfer case lower brace-to-transaxle bolts to 23 ft. lbs. (31 N.m).
Affix outboard and inboard drive shaft retaining rings onto output shaft. DO NOT push to hard during installation of output shaft, or damage to bushings or bearings may occur. Carefully install output shaft into transaxle. Extend shaft through differential side gear.