Honda 8-97033-097-0 Case Assembly, Transfer

On these models, the transmission/transfer case assembly is disassembled for overhaul as a single unit and thus wiser for an expert repair shop that handles both the transmission and the transfer case. A number of rebuilt units may be in the market, therefore a customer should consult the dealerships parts department and auto parts stores. Also, some amount of cost cutting is possible if the transmission/transfer case unit is removed and taken to the shop.

Cut the negative battery cable and take off the top part of the air cleaner housing from the air cleaner assembly to keep dust out while you tilt the engine back just enough to free the transfer case. Remove the center console, then take off the knobs from both the transmission and transfer case shift levers. Leave the shift lever base holding bolts in place for now. Pull off the shift lever only when you've unplugged it from the linkage. Raise the car on jack stands, place block under it so it stays in position. Unhook the shift lever from the gearbox buttons, lift up the shift lever system, detach all the electrical cables near the left side of the shift lever system, and put it away - don't disconnect any more than essential. Take off the skid plate and any exhaust parts that may get in the way when you take out the transfer case. Press escape from all wires, extensions, and pull back all wiringdone direct from the transfer case. Discard and disconnect all oils from the transfer case, then take apart the front and back driveshafts that run through the transfer case. Position the transfer case gently on a jack (designed for this job) with a block of wood placed between the jack's head and the transfer case, and use safety chains to keep everything stable. Note the type, size, length, and where you unscrew each bolt that holds the transfer case to the transmission. First, check that everything is disconnected from the top of the transmission/transfer case, and push the transfer case to the back to let the dowel pins fall out from the transmission. To put the transfer case in place, lift it onto the jack so it's steady, then apply a drop of moly grease to the input shaft before fitting it back. Move the transfer case forward until both dowel pins and the torque converter line up, then attach and fasten the adapter-to-transfer bolts and nuts. Reinstall the shift lever assembly, bolt it back in place, plug in wires you had disconnected, wire up the transmission lever to the shift lever, and fix the cable movement. Rephrase: Connect all transfer case wires as usual, after moving them out of the way. Reattach the electrical connections for the transfer case. Reinstall all exhaust pieces that were taken out or detached, put the transfer case tank back up to full, unkink the lifters, set the vehicle back down, replace the transfer case switching unit, and put the middle cabinet back in place.