Removal

1. WARNING: THE ELECTRICAL POWER TO THE AIR SUSPENSION SYSTEM MUST BE SHUT OFF PRIOR TO HOISTING, JACKING OR TOWING AN AIR SUSPENSION VEHICLE. THIS CAN BE ACCOMPLISHED BY TURNING OFF THE AIR SUSPENSION SWITCH LOCATED IN THE RH KICK PANEL AREA. FAILURE TO DO SO CAN RESULT IN UNEXPECTED INFLATION OR DEFLATION OF THE AIR SPRINGS, WHICH CAN RESULT IN SHIFTING OF THE VEHICLE DURING THESE OPERATIONS.

Raise and support the vehicle.





2. NOTE: Drain the transfer case if disassembly is required.

Drain the transfer case.
- Remove the drain plug.





3. NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft yoke and axle flange so they can be installed in their original positions.

Remove the rear driveshaft.
1 Remove the four bolts.
2 Remove the rear driveshaft.





4. Remove the front driveshaft shield.
1 Remove the nuts.
2 Remove the front driveshaft shield.
5. Remove the No. 3 and 4 crossmembers.





6. Disconnect the front driveshaft.
1 Remove the four front driveshaft flange bolts.
2 Disconnect the front driveshaft.
7. Remove the torsion bars and rear torsion bar support.





8. Remove the transfer case skid plate.
1 Remove the four bolts (two each side).
2 Remove the transfer case skid plate.





9. Disconnect the Vehicle Speed Sensor (VSS) electrical connector.





10. Disconnect the electric shift motor electrical connector.
11. Support the transfer case.
- Use a hi-lift jack.
- Secure the transfer case to the jack with a safety strap.





12. Remove the six transfer case to transmission bolts (three each side).
13. Lower the transfer case.