Installation Procedure
Clean the contact surfaces between the power transfer unit case and the transmission.
- Install a NEW power transfer unit case-to-transmission O-ring (1).
Support the power transfer unit case with a suitable jack, and secure with suitable straps.
- Raise and align the power transfer unit case in the correct position in relation to the transmission.
- Install the power transfer unit case (2) to the transmission.
- Install the power transfer unit case-to-transmission bolts (1) and tighten to 100 N.m (74 lb ft).
Install the transmission mount strut bracket bolts (1, 2). Transmission Mount Strut Bracket Replacement (All Wheel Drive) , or Transmission Mount Strut Bracket Replacement (Front Wheel Drive)
Connect the electrical connectors (1, 2), then install the wiring harness retainers (3) To the power transfer unit.
- Connect the two piece propeller shaft to the power transfer unit case. Two-Piece Propeller Shaft Replacement
- Power Transfer Unit Heat Shield - Install - Power Transfer Unit Heat Shield Replacement
Connect the transfer case vent hose (1) to the power transfer unit case (2).
Install the 2 transfer case bracket bolts (1) and tighten to 22 N.m (16 lb ft).
- Install the right wheel drive shaft. Front Wheel Drive Half Shaft Replacement - Right Side (AWD) , or Front Wheel Drive Half Shaft Replacement - Right Side (M3U, MHG, MNH, MNK with FWD) , or Front Wheel Drive Half Shaft Replacement - Right Side (M3D, M3H with FWD)
- Install the exhaust front pipe. Exhaust Front Pipe Replacement
- Check transmission fluid level. Transmission Fluid Drain and Fill , or Transmission Fluid Drain and Fill
- Check the power transfer unit case fluid level. Power Transfer Unit Case Fluid Replacement
Use care when installing the transfer case assembly to avoid contact with the pinion spline. Contact with the pinion spline may cause damage to the transfer case assembly.
Refer to Fastener Caution .