Removal

Special Tools:

REMOVAL
1. Raise and support vehicle.

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.





2. Drain the transfer case.
^ Remove the drain plug.

NOTE: Drain the transfer case if disassembly is required.





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

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





4. Remove the front driveshaft shield.
1 Remove the two front driveshaft shield nuts.
2 Remove the front driveshaft shield.





5. Disconnect the front driveshaft.
1 Remove the four front driveshaft flange bolts.
2 Disconnect the front driveshaft.

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

6. Remove the torsion bars and rear torsion bar support.





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





8. On manual shift vehicles, use the Shift Linkage Insulator Tool to disconnect the shift rod.





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





10. On manual shift vehicles, disconnect the 4WD indicator switch electrical connector.





11. On manual shift vehicles, disconnect the transfer case coil electrical connector.





12. On manual shift vehicles, disconnect the 4WD indicator switch.





13. On electrical shift vehicles, disconnect the electric shift motor electrical connector.
14. Support the transfer case.
^ Use a hi-lift jack.
^ Secure the transfer case to the jack with a safety strap.





15. Remove the six transfer case to transmission bolts (three each side).
16. Lower the transfer case.