Transfer Case Assembly Replacement

/ 9-5 (9650) / 2011 / 4. Transmission / All-wheel drive / Adjustment/replacement / Transfer Case Assembly Replacement

Special Tools

DT-48783 Special Adjustable Socket E18 Extended

For equivalent regional tools, refer to Special Tools .

Removal Procedure

1.	Remove the propeller shaft. Refer to Propeller Shaft Replacement .

2.	Manual transmission: Drain the transmission fluid. Refer to Transmission Fluid Replacement .

3.	Automatic transmission: Drain the transmission fluid. Refer to Transmission Fluid Level and Condition Check .

4.	Release the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

5.	Remove the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .

6.	Remove the subframe. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

7.	Remove the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement .

8.	Remove the bleed hose, if equipped.

9.	Remove the support bracket fasteners (1).

10.	Remove the support bracket to engine fasteners (2).

11.	Support the transfer case with a column jack, and secure with cable ties.

12.	Remove the transfer case fasteners (3) using special socket DT-48783.

13.	Lower and ease out the transfer case.

Installation Procedure

1.	Clean the contact surfaces between the transfer case and the gearbox. Fit a new O-ring.

2.	Raise and align the transfer case in the correct position in relation to the gearbox.

3.	Refer to Fastener Caution . Fit the transfer case. Tighten the bolts in the correct order as illustrated. Tighten 110 Nm (81 lb ft)

4.	Fit the support bracket between the transfer case and the engine carefully in three steps to avoid breakage.

5.	Tighten the support bracket fasteners (1). Tighten 5 Nm (44 lb in)

6.	Tighten the support bracket to engine fasteners (2).

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For LBW/A28NET: 22 Nm (16 lb ft)

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For LDK/A20NHT and LBY/A20DTR: 60 Nm (44 lb ft)

7.	Tighten the support bracket fasteners (1). Tighten 60 Nm (44 lb ft)

8.	Install the bleed hose, if equipped.

9.	Install the transmission rear mount bracket. Refer to Transmission Rear Mount Replacement .

10.	Install the subframe. Refer to Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNA) Drivetrain and Front Suspension Frame Front Crossmember Replacement (GNB) .

11.	Install the front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .

12.	Install the right drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side (GNB) Front Wheel Drive Shaft Replacement - Right Side (Petrol) .

13.	Install the propeller shaft. Refer to Propeller Shaft Replacement .

14.	Manual transmission: Fill the transmission with oil. Refer to Transmission Fluid Replacement .

15.	Automatic transmission: Fill the transmission with oil. Refer to Transmission Fluid Level and Condition Check .

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