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Transfer Case Removal / Installation

  1. With the vehicle in NEUTRAL, position it on a hoist. See LIFTING .
  2. Remove the four bolts and the skid plate.
    Fig 1: Skid Plate Bolts With Torque Specifications
    G04309019Courtesy 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
    G04309020Courtesy 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: Removing/Installing Drain Plug With Torque Specifications
    G04309021Courtesy 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
    G04309022Courtesy of MAZDA MOTORS CORP.
    1. Index-mark the front output shaft assembly and the front driveshaft constant velosity (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 (4WD) 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: Removing Transfer Case Bolts
    G04309023Courtesy 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: Front Extension Housing Gasket
    G04309024Courtesy of MAZDA MOTORS CORP.
  12. Install the new gasket on the front of the transfer case.
    Fig 7: Front Extension Housing Gasket
    G04309025Courtesy 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: Installing Transfer Case To The Extension Housing With Torque Specifications
    G04309026Courtesy 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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