Four-wheel drive vehicles rely on a transfer case to operate properly. The transfer case is connected to the vehicle's transmission and the front and rear axles by way of drive shafts. If you are having problems with the four-wheel drive on your truck or SUV, it is may be due to a worn out transfer case. Rather than spending a lot of money to buy a new one, you can rebuild your existing transfer case.
Raise your vehicle with four heavy duty jacks. Use one jack for each of the vehicle's wheels. You will have to slide underneath the SUV or truck to do your work.
Use an electric hand-held drill to remove the bolts that hold the skip plate into place. This component houses the transfer case in the vehicle. Set the plate and bolts aside.
Locate the drain plug on the transfer case that holds fluid inside to keep the case lubricated. Open the plug to drain the liquid from the transfer case.
Use a wrench to remove the nuts and bolts from four-wheel drive sensor, rear drive shaft, front drive shaft and shifter linkage. After these items are out of the vehicle, you will be able to remove the transfer case. Use wrenches, pliers and screwdrivers to remove the bolts and screws holding the items in place and set them aside while you concentrate on the transfer case. Remove the sensor and disconnect the hose.
Loosen and remove the bolts on the cover of the transfer case with the electric hand-held drill to remove it. Remove the retaining clip slide out of the case oiler from the shaft as well. Apply your pliers inside the lid to remove the clip.
Use the drill to remove the bolts holding the snap ring, viscous clutch coupling, output shaft drive, chain, drive gear, front output drive gear, shifter shaft, input shaft seal retainer, input shaft snap ring, output flange, output shaft and input shaft (in that order) in place. The rebuild kit will contain each of these parts, which you will then replace in the transfer case.
Install the new parts included in the rebuild kit. Add transmission fluid to lubricate the components as you install them.
Close up the transfer case by reinserting the oiler disc and snap the retainer clip back in place. Align the cover on the case by using a torque wrench to tighten the bolts back on.
Replace the transfer case back in its proper position in the vehicle. Secure the bolts holding it into place with a wrench or electric drill. Remove the plug cap and fill the case with the appropriate amount of transmission fluid and put the plug back into place.
