Removal/Installation

Fig. 1 Shifter & Shift Lever Mounting. Except Bravada, Sonoma GT, Syclone & Typhoon:

EXCEPT BRAVADA, SONOMA GT,
SYCLONE & TYPHOON

Removal
1. Position transfer case shift lever at 4 Hi.
2. Disconnect battery ground cable.
3. Raise and support vehicle.
4. Remove skid plate, if equipped and drain transfer case.
5. Remove front and rear propeller shafts.
6. Remove speedometer cable and shift linkage at transfer case.
7. Remove catalytic converter front bracket bolts and loosen front converter clamp.
8. Remove rear transmission mounting bolts.
9. Support transmission with a jack then raise transmission and transfer case.
10. Remove catalytic converter front bracket.
11. Lower transmission and transfer case.
12. Support transfer case with a jack.
13. Remove transmission-to-transfer case retaining bolts. On models equipped with automatic transmission, remove shift lever bracket mounting bolts, Fig. 1, to gain access to upper left side transfer case mounting bolt.
14. Separate transfer case from transmission then remove gasket.

Fig. 5 Transfer Case Installation. Except Bravada, Sonoma GT, Syclone & Typhoon:

Installation
1. Position new gasket on transfer case as shown in Fig. 5.
2. Position transfer case near end of transmission, then align transfer case input shaft splines with transmission splines and slide transfer case forward until seated against transmission.
3. Install transfer case attaching bolts. Torque bolts to specifications. On models equipped with automatic transmission, install shift lever bracket mounting bracket bolts.
4. Raise transmission and transfer case assembly with a jack, then install mount and catalytic converter hanger bracket. Lower transmission and transfer case assembly.
5. Install transmission rear mounting bolts and torque to specifications.
6. Install and tighten catalytic converter hanger bolts and front clamp.
7. Install shift lever to transfer case, then connect speedometer cable.
8. Install front and rear driveshafts.
9. Install skid plate.
10. Fill transfer case with lubricant and lower vehicle.
11. Connect battery ground cable.


BRAVADA, SONOMA GT,
SYCLONE & TYPHOON

Fig. 6 Transfer Case & Adapter Installation. Bravada, Sonoma GT, Syclone & Typhoon:

Refer to Fig. 6, for transfer case replacement.
1. Disconnect battery ground cable.
2. Raise and support vehicle, then drain oil from transfer case.
3. Remove front and rear propeller shafts.
4. Disconnect vent hose and electrical connections at transfer case.
5. Support transfer case using a suitable jack, then remove transfer case support brace and bracket.
6. Remove transfer case bolts, then the transfer case mount nuts and washers.
7. Remove transfer case, then the transfer case to adapter gasket.
8. Reverse procedure to install.