Question about 2000 Mazda B-Series

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2000 mazda b2500 4wd, cab chassis ute. how do you disassemble transfer case from gearbox. have taken off selector cover to find theres nothing to remove off selectors to free the transfer

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  • nadia_bizzot May 23, 2011

    hello. your description has not got the information i wanted on how to remove transfer case from the gearbox

  • nadia_bizzot May 24, 2011

    hi. the transfer only slides aprox 10mm it seems to stop by a centre gear shaft connecting the 2, as well as it still connected to the gearbox selector shaft

  • nadia_bizzot May 24, 2011

    cheers mate. got it out, but the info didnt say to punch the pin out of selector shaft from gearbox which free's the transfer. thanx

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  • Master
  • 3,917 Answers

Hi

Removal & Installation of Transfer Case Assembly

To Remove:
-Put vehicle in NEUTRAL then raise and safely support the vehicle.
-Remove the skid plate.
-If equipped, remove the damper.
-Disconnect the transfer case harness connector.
-If disassembly of the transfer case is necessary, remove the drain plug and drain the fluid. Once all of the fluid has drained, install the plug
-Torque to 18 ft-lb (24 Nm).
CAUTION
Make alignment marks on the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
CAUTION
Make sure to first disconnect the front driveshaft from the transfer case for this procedure. Failure to do this can cause the weight of the driveshaft to pinch the boot between the shaft and the boot can, which can cause the boot to tear.
-Disconnect the front driveshaft from the transfer case.
NOTE: Make alignment marks on the front flange on the rear driveshaft and the flange on the transfer case.
-Remove the rear driveshaft.
CAUTION
Make sure to use safety straps to secure the transfer case to the jack.
-Place an appropriate jack under the transfer case.
-Remove the transfer case.
To Install:
NOTE: Make sure to use a new gasket when installing the transfer case.
NOTE: Torque the bolts that fasten the transfer case to the extension housing in a clockwise direction starting with the upper left-hand bolt.
NOTE: During installation of the front driveshaft, always connect it to the axle first, then to the transfer case.
NOTE: The front driveshaft should be installed with new washers and bolts and the rear driveshaft with new bolts. In the event new bolts are unavailable, use threadlock and sealer to coat the threads of the existing bolts.
NOTE: When installing both the front and rear driveshafts, use the alignment marks made during removal.
-Install the transfer case.
Torque to 40 ft-lb (54 Nm).
-Remove the jack from under the transfer case.
-Install the rear driveshaft.
-Connect the front driveshaft to the transfer case.
Torque to 22 ft-lb (30 Nm).
-If needed, fill the transfer case with the correct type and amount of fluid.
-Connect the transfer case harness connector.
-If equipped, install the damper.
Torque to 25 ft-lb (34 Nm).
-Install the skid plate.
Torque to 18 ft-lb (24 Nm).
-Safely lower the vehicle.

Please get back to us if you have further query else please accept the suggestion.
Thank you for contacting fixya.com

Posted on May 23, 2011

  • e-Guru
    e-Guru May 23, 2011


    Hi,



    Sorry for the inconvenience. The transfer case is located behind the transmission, just in front of the center of the vehicle. Apply the parking brake. Lift the front of the vehicle using the jack and put jack stands under the vehicle. Put a drain pan underneath the transfer case. Open up the drain plug on the transfer case with the 3/8-inch ratchet and socket, and then let the transfer case oil empty into the pan.

    Unbolt the rear drive shaft from the axle with an open-end wrench, and then pull the end out of the axle. Slide the rear drive shaft out of the transfer case. Unbolt the front drive shaft from the front axle using an open-end wrench. Pull the front drive shaft out of the axle, and then slide it out of the transfer case.

    Unplug any electrical connections that may be present using your hands and then remove the vent hoses using a pair of pliers. Disconnect the shift linkage from the case with the 3/8-inch ratchet and socket. Lift the transmission jack up underneath the transfer case and wrap the chains from the jack around the transfer case.

    Unbolt the transfer case from the transmission using an open-end wrench and the 3/8-inch ratchet and socket. Slide the transfer case away from the transmission with the jack. Lower the transmission jack and slide the transfer case out from underneath the vehicle.

    Your vehicle is a 4WD Mazda B2500; the transfer box will have to be removed first. Remove the starter motor from the engine by undoing the three bolts attaching it.

    There are thirteen bolts holding the gearbox to the engine. Remove those bolts and the transmission mount, as well as its damper. Remove the bolts from the cross-member and remove the cross-member.

    Lower the jack to angle the gearbox downwards and carefully remove the gearbox from the engine/clutch.

    Remember, when you need to refit the gearbox, check all the wiring and the condition of the wires. Torque up the gearbox bolts to the correct settings and use a clutch alignment tool if necessary.



    Please get back to us if you have further query else please accept the suggestion.
    Thank you for contacting fixya.com




    Hi,


    Sorry for the inconvenience. The transfer case is located behind the transmission, just in front of the center of the vehicle. Apply the parking brake. Lift the front of the vehicle using the jack and put jack stands under the vehicle. Put a drain pan underneath the transfer case. Open up the drain plug on the transfer case with the 3/8-inch ratchet and socket, and then let the transfer case oil empty into the pan.

    Unbolt the rear drive shaft from the axle with an open-end wrench, and then pull the end out of the axle. Slide the rear drive shaft out of the transfer case. Unbolt the front drive shaft from the front axle using an open-end wrench. Pull the front drive shaft out of the axle, and then slide it out of the transfer case.

    Unplug any electrical connections that may be present using your hands and then remove the vent hoses using a pair of pliers. Disconnect the shift linkage from the case with the 3/8-inch ratchet and socket. Lift the transmission jack up underneath the transfer case and wrap the chains from the jack around the transfer case.

    Unbolt the transfer case from the transmission using an open-end wrench and the 3/8-inch ratchet and socket. Slide the transfer case away from the transmission with the jack. Lower the transmission jack and slide the transfer case out from underneath the vehicle.

    Your vehicle is a 4WD Mazda B2500; the transfer box will have to be removed first. Remove the starter motor from the engine by undoing the three bolts attaching it.

    There are thirteen bolts holding the gearbox to the engine. Remove those bolts and the transmission mount, as well as its damper. Remove the bolts from the cross-member and remove the cross-member.

    Lower the jack to angle the gearbox downwards and carefully remove the gearbox from the engine/clutch.

    Remember, when you need to refit the gearbox, check all the wiring and the condition of the wires. Torque up the gearbox bolts to the correct settings and use a clutch alignment tool if necessary.


    Please get back to us if you have further query else please accept the suggestion.
    Thank you for contacting fixya.com


  • e-Guru
    e-Guru May 24, 2011

    Hi,

    I have given you a detailed step of the removal of the transfer case in this type of vehicle. Please check the procedure thoroughly. I am sure you have missed out some points for which you are having such problem. Kindly check all the nooks and corners, the problem must be lying somewhere there cause its very complex yet easy to perform the job. As is said earlier unbolt the transfer case from the transmission using an open-end wrench and the 3/8-inch ratchet and socket. Slide the transfer case away from the transmission with the jack. Lower the transmission jack and slide the transfer case out from underneath the vehicle. Your vehicle is a 4WD Mazda B2500; the transfer box will have to be removed first. Remove the starter motor from the engine by undoing the three bolts attaching it.

    There are thirteen bolts holding the gearbox to the engine. Remove those bolts and the transmission mount, as well as its damper. Remove the bolts from the cross-member and remove the cross-member. Lower the jack to angle the gearbox downwards and carefully remove the gearbox from the engine/clutch.

    Please get back to us if you have further query else please accept the suggestion.
    Thank you for contacting fixya.com


    Hi,

    I have given you a detailed step of the removal of the transfer case in this type of vehicle. Please check the procedure thoroughly. I am sure you have missed out some points for which you are having such problem. Kindly check all the nooks and corners, the problem must be lying somewhere there cause its very complex yet easy to perform the job. As is said earlier unbolt the transfer case from the transmission using an open-end wrench and the 3/8-inch ratchet and socket. Slide the transfer case away from the transmission with the jack. Lower the transmission jack and slide the transfer case out from underneath the vehicle. Your vehicle is a 4WD Mazda B2500; the transfer box will have to be removed first. Remove the starter motor from the engine by undoing the three bolts attaching it.

    There are thirteen bolts holding the gearbox to the engine. Remove those bolts and the transmission mount, as well as its damper. Remove the bolts from the cross-member and remove the cross-member. Lower the jack to angle the gearbox downwards and carefully remove the gearbox from the engine/clutch.

    Please get back to us if you have further query else please accept the suggestion.
    Thank you for contacting fixya.com

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REMOVAL & INSTALLATION CAUTION
The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the extremely high temperatures generated by the converter.
  1. Disconnect the negative battery cable.
  2. Raise the vehicle and support it safely.
  3. If so equipped, remove the skid plate from frame.
  4. Drain the transfer case.
  5. Remove the damper from the transfer case, if so equipped.
  6. On electronic shift models, remove the wire connector from the feed wire harness at the rear of the transfer case. Be sure to squeeze the locking tabs, then pull the connectors apart.
  7. Disconnect the front driveshaft from the axle input yoke.
  8. If equipped, loosen the clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft.
  9. Disconnect the rear driveshaft from the transfer case output shaft yoke.
  10. If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
  11. If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
  12. Disconnect the vent hose from the mounting bracket.
  13. On manual shift models, perform the following:
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    2. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
  14. If equipped, remove the heat shield from the transfer case.
  15. Support the transfer case with a transmission jack.
  16. Remove the mounting bolts retaining the transfer case to the transmission.
  17. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket or any old sealer from between the transfer case and the transmission.

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