Service Manual

2.18
MAINTENANCE
Main Gearcase - Lubricant Level Check:
The fill plug is located on the side of the gearcase just below the
shift lever bell crank. Maintain the fluid level even with the
bottom of the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill plug.
3. Check the fluid level.
4. If fluid level is not at fill plug hole, add the recommended
fluid as needed.
5. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
Transmission Lubricant Change:
The lubricant change procedure is relatively the same for the
main gearcase and the transfer case. To minimize confusion,
perform the lubricant change on only one gearcase at a time.
Access the drain plugs through the drain holes in the skid plate.
Transfer Case Lubricant Change:
1. Remove the fill plug and the level check plug (refer to
“Transfer Case - Lubricant Level Check”).
2. Place a drain pan under the transfer case drain plug.
3. Remove the drain plug and allow to drain completely.
4. Clean the drain plug.
5. Reinstall the drain plug with a new o-ring and torque to
30-45 in. lbs. (3-5 Nm).
6. Add the recommended fluid through the fill plug hole until
it begins to flow out the check plug hole. Do not overfill.
7. Reinstall the level check plug and torque to 30-45 in. lbs.
(3-5 Nm).
8. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
Main Gearcase Lubricant Change:
9. Remove the fill plug (refer to “Main Gearcase - Lubricant
Level Check”).
10. Place a drain pan under the main gearcase drain plug.
11. Remove the drain plug and allow to drain completely.
12. Clean the drain plug.
13. Reinstall the drain plug with a new o-ring and torque to
30-45 in. lbs. (3-5 Nm).
14. Add the recommended fluid through the fill plug hole.
Maintain the fluid level at the bottom of the fill plug hole
when filling the Main Gearcase. Do not overfill.
15. Reinstall the fill plug and torque to 40-50 ft. lbs.
(54-68 Nm).
16. Check for leaks. Discard the used lubricant properly.
Fill Plug /
Level Check Plug
Main Gearcase
Drain Plug
Transfer Case
Drain Plug