Captiva

Transfer Case Assembly Replacement

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the exhaust front pipe.
3. Remove the propeller shaft.
4. Remove the right drive axle.



5. Remove the upper transfer case bolt (1).
6. Remove the transfer case brace bolts (3) and the brace (2).
7. Remove the transfer case bracket bolts (5, 6) and the bracket (4).



8. Remove the lower transfer case bolts (1).
9. Support the transfer case using the supporting jack.



10. Remove the transaxle rear mount-to-bracket through bolt (1).
11. Remove the rear transaxle bracket mounting bolts and nuts (2).



12. Remove the transaxle rear mount retaining bolts from the cradle.
13. Remove the rear transaxle bracket.



14. Remove the transfer case from the transaxle.
15. Remove the transfer case to transmission O-ring, then discard the O-ring.
16. Plug the transaxle to minimise the transaxle fluid loss.

Note: Transmission fluid may creep from the transmission bore during installation.

1. Thoroughly clean the transmission bore and ribbing of fluid and debris immediately prior to installing the transfer case.
2. Install a NEW transfer case to transmission O-ring.



3. Install the transfer case from the transaxle.



4. Install the rear transaxle bracket.

Caution: Refer to Fastener Caution in the Preface section.

5. Install the transaxle rear mount retaining bolts from the cradle and tighten to 90 N·m (66 lb ft).



6. Install the transaxle rear mount-to-bracket through bolt (1) and tighten to 90 N·m (66 lb ft).
7. Install the rear transaxle bracket mounting bolts and nuts (2) and tighten to 90 N·m (66 lb ft).



8. Install the lower transfer case bolts (1) and tighten to 75 N·m (55 lb ft).



9. Install the upper transfer case bolt (1) and tighten to 75 N·m (55 lb ft).
10. Install the transfer case brace (2) and bolts (3) and tighten to 60 N·m (44 lb ft).
11. Install the transfer case bracket (4) and bolts (5) and tighten to 60 N·m (44 lb ft).
12. If the vehicle is equipped with a 3.2L engine, install the transfer case bracket bolt (6) and the other 4 bolts (5) and tighten.

Tighten

•	Transfer case bracket bolt (6) to 40 N·m (30 lb ft).

•	The other 4 bolts (5) to 60 N·m (44 lb ft).




13. Install the right drive axle.
14. Install the propeller shaft.
15. Install the exhaust front pipe.



16. Lower the vehicle.
17. Check the transaxle oil level and fill as required.