Chapter 2- Drive System: CVT and Transfer Case
27
DRIVE SYSTEM SERVICE: TRANSFER CASE
REMOVAL WITH KOHLER ENGINE
1. Remove the cargo box from the vehicle:
See Figure 2.44.
1a. Lift and support the cargo box.
1b. Pry-off the retainer that holds the lift assist
cylinder to the cargo box.
1c. Carefully lower the cargo box. Use a length
of 2X4 dimensional lumber to block the
latch that normally secures the cargo box
in the down position.
1d. Remove the nuts and bolts that secure the
cargo box to the frame using a pair of 9/
16” wrenches.
1e. With the help of an assistant or a mechani-
cal lifting device, slide the cargo box off
the back of the frame and remove it from
the vehicle.
2. Lift and safely support the vehicle.
3. Release the Camloc
R
fasteners that secure the
engine cover and remove the engine cover.
Figure 2.44
Attachment clip
Cargo box
hinge bolt
(1 per side)
Lift assist
cylinder
4. Disconnect the black cable from the negative
terminal on the battery using a 10mm wrench.
5. Remove the CVT belt and pulleys as described
in the DRIVE SYSTEM: CVT BELT AND PUL-
LEYS section of this manual. See Figure 2.45.
6. Remove the four bolts that hold the heavy steel
engine / transmission plate using a 1/2” wrench.
7. Remove the four bolts that hold the engine /
transmission plate to the engine using a 9/16”
wrench. The bolts pass through a spacer
between the plate and the engine.
NOTE: It is not necessary to remove the univer-
sal joint guard from the plate.
8. Carefully lift the plate out of the engine bay. It is
most easily removed through the opening under
the passenger’s seat. See Figure 2.46.
Figure 2.45
CVT
removed
Figure 2.46
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