How do i remove transfer case from a 2004 Mitsubishi Endeavor?
Year: 2004Make: MitsubishiModel: EndeavorEngine: 3.8
Removal of bolts and pulling out.
Removed bolts, driveshafts, and tried to remove. Came out about 1 1/2" and stopped. I have the same manual. Does it "pop out" or should it just slide right out?
you have to pry it out it should slide right out .use a prying bar.
Tried that several times. Is there any retaining clip on the inside of the transaxle holding the splines together?
no that is it just the spline gear nothing holds it inside
Well thanx anyways!
Have you disengaged the transfer case shaft splines yet?
If you have not done this, prying on the transfer case is not a good idea. The transfer case is internally fixed to the transmission here.
How do you do that?
A slide hammer is the easiest method. If you look at each output shaft, you will see a threaded hole on the exposed ends. This hole normally uses a special tool that threads in with a slidehammer type handle. Once full engaged in the thread, one good tap of the slide hammer and the splined shafts will disengage the transmission and slide out.
Not having the appropriate tool, the next best thing is going to be to find a spare bolt that threads into the shaft, and bolt a long piece of scrap steel to the shaft. You can then use a mallet to tap the shaft out.
You could also bolt a U shaped bracket or similar onto the shaft, then use a slidehammer with a right-angle attachment to hook the bracket and pull it out.
The shafts use a standard C-clip like you see on most FWD transmissions, but is engaged past the transfer case and into the transmission. Without removing the shafts, you will only be able to get the transfer case about an inch away from the transmission.
Thank You so very much! The last guy told me everything should just fall out, and read the same manual I have word for word back to me! I will accept as soon as I get it out! You are correct, I can only get it about an inch outside the case. Once again, THANK YOU SO VERY MUCH!
THe output shaft removal is not documented... pretty much anywhere. Even the Factory service manuals do not have it, only the technician private manuals are the only places I have seen it referenced. It's not the previous persons fault, they were just going by what they read... you would have to be a Mitsubishi employee or work on that model specifically to know about them.
Be sure to check the large O-ring on the transfer case once it is out... if you gave a decent amount of prying that o-ring and the leading age may have taken a bit of damage. Nothing you can't file down and replace the o-ring with though.
If you have any problems, let me know. When you are all done, please remember to click Accept to credit my time.
Good luck with your repair!
16 years automotive and OTR repair including specialized training from Toyota and Mitsubishi