Transfer Case Removal/Installation

With the vehicle in NEUTRAL, raise the vehicle on a hoist.
Remove the four bolts and the skid plate.

Fig 1: Removing Skid Plate
Courtesy of MAZDA MOTORS CORP.
Remove the four bolts and the damper; see DAMPER REMOVAL/INSTALLATION .
Disconnect the electronic shift motor harness connector and position aside.

Fig 2: Disconnecting Electronic Shift Motor Harness Connector
Courtesy of MAZDA MOTORS CORP.
If disassembly is required, remove the drain plug and drain the transfer case. Replace the drain plug when fluid has drained.

Fig 3: Removing Drain Plug
Courtesy 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.

Fig 4: Disconnecting Front Driveshaft From Transfer Case

Courtesy of MAZDA MOTORS CORP.

Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
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.

WARNING: Secure the transfer case to the jack with safety straps.

Remove the rear propeller shaft. See REAR PROPELLER SHAFT (4X4) REMOVAL/INSTALLATION or REAR PROPELLER SHAFT (4X2) REMOVAL/INSTALLATION .
Position a high lift jack under the transfer case.
Remove the five bolts retaining the transfer case to the extension housing.

Fig 5: Extension Housing Bolts
Courtesy of MAZDA MOTORS CORP.
Slide the transfer case rearward and off of the transmission output shaft.
Remove and discard the front extension housing gasket and clean the mating surfaces.

Fig 6: Front Extension Housing Gasket
Courtesy of MAZDA MOTORS CORP.
Install the new gasket on the front of the transfer case.

Fig 7: Installing Front Extension Housing Gasket
Courtesy 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.

Fig 8: Transfer Case Bolt Tightening Sequence

Courtesy of MAZDA MOTORS CORP.

Install procedure in reverse order of removal.
Check and, if necessary, fill the transfer case with the specified type and quantity of fluid. See LUBRICATION .