Front Axle Flange Repair Procedures

Removal

Be careful when handling the transfer case. Prevention of ITA (Integrated Transfer Actuator) Damage 1) When transporting the transfer case Be careful when lifting the transfer case with a transport package to ensure the ITA does not collide with another transfer case. Be careful not to let the floor or structure strike the ITA. 2) When assembling the transmission Be careful not to damage the ITA by contact with the transmission, floor or structure.

1. 1
   Remove the transfer case from the vehicle. (Refer to All Wheel Drive (AWD) System - "Transfer Case Assembly")
2. 2
   Loosen the filler plug (A) and drain the oil.

   

3. 3
   Install the slide hammer to the flange (A).
4. 4
   Pull out the flange (A).

   

5. 5
   Remove the radial oil seal (A).

   

Installation

1. 1
   Install the radial oil seal on the installation tool.
2. 2
   Tap the plastic ring against the transfer case housing.

   

3. 3
   Place the snap ring into the flange groove.

   

4. 4
   Insert the new flange (A) into the transfer case by lightly tapping with a plastic hammer.

   

5. 5
   Fill with oil up to the lower edge of the filler plug hole (of the installed transfer case). Tighten the plug to 60 N·m.

   Oil type: Shell TF0870

   Replace the gasket before reinstalling the filler plug.

6. 6
   Install the transfer case on the vehicle. (Refer to All Wheel Drive (AWD) System - "Transfer Case Assembly")
7. 7
   After installation, start the engine, then check for leaks from the transfer case.