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Loosen Transfer Case Drain Plug
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Using your 17mm wrench or socket, loosen the drain plug.
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Completely Remove Drainplug
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After removing the drainplug, you should have a 1/3 to 2/3 of
a quart drain out. Catch this oil in an empty container.
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Mark the Driveshaft
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Using a wax crayon, tire marker, or other marking tool, make mating
marks along the entire driveshaft. Also extend the mark to the
flange at the differential. Doing this allows you to reassemble
and/or reinstall the driveshaft in exactly the same orientation
as it was originally on the car. You may never need to do this,
but it can't hurt.
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Unbolt Exhaust Hanger
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There is an exhaust hanger close to the front carrier assembly.
You'll need to remove it in order to allow the driveshaft
to be removed from the car. They are all 12mm bolts and there
are 4 of them. If you're in a hurry, you can unbolt 3 of them and
just let the hanger hang there.
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Support the Driveshaft
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Find some way to support the driveshaft, as you're going to unbolt
it and it will drop down if not supported. I had some extra
jack stands that worked great.
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Unbolt Front Carrier
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Using a 14mm socket (you'll need a deep one, as shown), unbolt
the front carrier. Again, make sure you support the front section of the
driveshaft now, as it will be hanging there somewhat unsupported.
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Unbolt Rear Carrier
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Unbolt the rear carrier just like you did the front one.
For the nut on the driver's side, there are clearance
"challenges," so you may need a universal joint for your
socket wrench. I also found that a 14mm closed-end ratcheting
wrench worked very well here. After unbolting the carrier,
you'll need to support the center section of the driveshaft.
I used another jack stand for this.
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Disconnect Rear Differential Flange
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The last connection on the driveshaft is the rear flange that mates
to the rear differential flange. The bolt heads are 12mm and the
nuts on the back side are 14mm. If you don't have enough leverage
to break the nuts free, then you can attach a second, larger wrench
to the 14mm wrench and pull on it. That's what I did. You can also
brace the 12mm wrench against part of the differential support so you
don't have to have a hand on that wrench. Finally, if you have trouble
with the driveshaft moving as you try to break the nuts free, then
you can either apply the e-brake or have a friend step on the brake
pedal to keep everything still.
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Lower the Rear Section of the Driveshaft
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Be careful - it's a little awkward and weighs in the neighborhood of 20lbs.
You'll need to push the shaft toward the front of the car about 1/4" to get
the shaft to clear the differential flange. At this point, the rear of the
shaft will be completely free. Move your support jack stands (or whatever
you used to support the driveshaft) and lay the driveshaft flat on the ground
as you move toward the front of the car. I found it easier to lay the
driveshaft on a creeper so that I would have the heaviest (rear) section
on wheels when I removed it from under the car.
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Disconnect Front of Driveshaft
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Removing the front of the driveshaft from the transfer case is
really easy. Just pull gently toward the rear of the car and
it will slide right out. Be careful when it is first disconnected,
as there may be some residual oil in the splines of the driveshaft.
After most of it has dripped out, you can stuff a paper towel
or something similar into the yoke of the driveshaft to keep from
dripping tranny fluid everywhere.
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Replace Transfer Case Drain Plug
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The transfer case should be basically empty at this point, so
you can replace the drain plug. The tightening torque
is 22 ft*lbs, so don't over-tighten it! If you think you may
forget to refill the case, now would be a good time to
remove the fill plug and put it somewhere to remind you
to fill the transfer case before driving the car!
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Compare Old and New Driveshafts
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Just to double-check things, make sure that you compare both
driveshafts. They should be the same length, and the
carrier bearing on the new shaft should line up with the
location of the front carrier bearing of the old shaft.
Note that the 5-speed shaft is about 1" shorter than the
shaft for the 6-speed cars, so if the new shaft is about
an inch off from the old one, check your receipt to be sure
you got the right one!
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Install Rubber Carrier
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If you bought a 2-piece driveshaft, then you'll need to install
the rubber carrier onto the carrier bearing on the rear of the
front section of the driveshaft. If you find it difficult to install,
a bit of dish soap or WD-40 may help lubricate things to make
it easier. Make sure you install the carrier in the correct orientation -
there should be a piece of tape (and an arrow engraved into the metal
flange) that indicates the direction of the front of the car.
Note: Prior to shipping my shaft, PST was indicating that
the arrow on the carrier pointed toward the front of the car. The
message on the piece of tape (see pictures) also indicated this.
That is incorrect. Unless the arrow on the carrier changes
at some point, it should point toward the rear of the car. If
you're confused, hold the carrier so that the flanges are parallel
to the floor (flat) and the lip on these flanges curves downward. In
this position, the side of the carrier that is higher (farther from the
floor) goes on the driver's side of the car.
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Connect the Two Halves of the Driveshaft
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After installing the carrier on the front section of the shaft, it's
time to connect the two halves of the shaft. Note that the carrier is
installed backwards in this picture as the arrow is pointing toward
the front of the car, and the passenger's side flange is clearly higher
than the driver's side flange. Line up the mating marks on the two
halves of the shaft (see red or yellow lines second picture). The halves
should slide together pretty easily once you have aligned the splines.
This bears mentioning a second time: Make sure that you align the mating
marks on the two halves of the shaft; the shaft was balanced in this
position, and you may get driveline vibration if you don't align the marks.
The first and third pictures (cardboard background) above do not show the
marks aligned correctly, but the close-up picture does.
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[optional] Assemble Carrier Spacers
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If you chose to replace the rubber parts of your spacers for
the carrier assembly, now is the time to replace them. The upper
spacer has a metal bushing that presses into it, so you'll need
to reuse that part from your car. It should press out and back
in with moderate force from your hands. A press is not necessary.
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Install Spacers Onto Carrier
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Install the spacers as they were on the OEM part.
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Lubricate Driveshaft Yoke
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This probably isn't necessary, but it can't hurt. Smear a little
tranny fluid on the outside of the yoke on the driveshaft. This
makes it very unlikely that the yoke will "catch" on the output
seal of the transfer case and destroy the seal.
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Install Driveshaft
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After slipping end of the driveshaft yoke into the transfer case, support
the driveshaft and align the carrier assembly with the studs
on the car. Then support the rear of the driveshaft and attach
the rear flange to the differential. Then bolt the carrier assembly
onto the studs. Note that the bolts/nuts on the differential flange
should be tightened to 36-43ft*lbs and the nuts on the carrier assembly
should be tightened to 22 ft*lbs. Tighten the bolts on the
differential flange in a cross-pattern like you would lug nuts.
Make sure to reattach your
exhaust hanger after everything is bolted in place.
Note that the lower two pictures are shown with the rear section
of the driveshaft removed so that the carrier assembly is more
visible. These pictures are taken from the rear of the car,
so you can see that the carrier flange on the driver's side
needs to be higher than the one on the passenger's side.
Obviously, the rear half of the driveshaft needs to be
installed for the car to be driven :-)
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Refill Transfer Case
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Refill the transfer case with the appropriate amount of fluid. My 6-speed
transfer case took about 1/2 of a quart until fluid began to fun out
of the fill hole. For the 5-speed transfer case, the fluid should be filled
until the level is just a few millimeters below the check plug hole.
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