4R100 Transmission

Transfer Case - 4R100 Transmission

Special Tool(s):

Removal

1. With the vehicle in NEUTRAL, raise and support the vehicle.

NOTE: Drain the transfer case if disassembly is required.






2. Remove the drain plug and drain the transfer case.
3. Remove the skid plate, if equipped.

NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft.

4. Remove the rear driveshaft.






5. Remove the two nuts and the front driveshaft shield.

NOTE: To maintain initial driveshaft balance, index-mark the front driveshaft.

6. Remove the front driveshaft.






7. Make preliminary adjustment references.
1. Index-mark the torsion bars to the torsion bar crossmember.
2. Measure and record the torsion bar adjuster bolt length.






8. Remove the bolts.






9. Using the special tools, remove the torsion bar adjustment nuts.
- Tighten the special tool until the torsion bar adjuster lifts off the adjuster nut.






10. Remove the six bolts, then remove the torsion bar adjusting brackets.
- Move the torsion bar crossmember rearward. Place a hand under the torsion bar adjusting bracket. The bracket will slide off the torsion bar. Do one side at a time. Position the torsion bar crossmember against the frame support.






11. Pull the torsion bar rearward and separate it from the lower control arm. Remove the RH torsion bar only.
12. Remove the torsion bar crossmember.






13. On manual shift vehicles, using the special tool, disconnect the shift rod.






14. On manual shift vehicles, disconnect the 4WD indicator switch electrical connector, if equipped.






15. Disconnect the electric shift motor electrical connector, if equipped.






16. Disconnect the vent hose.






17. Using a suitable jack, support the transfer case.
- 8ecure the transfer case to the jack with a safety strap.






18. Remove the two exhaust heat shield-to-crossmember bolts.






19. Loosen, but do not remove, the transmission mount-to-crossmember nuts.






20. Remove the six crossmember-to-frame nuts and bolts.






21. Remove the transmission mount-to-crossmember nuts and the crossmember.






22. Remove the transmission mount and the exhaust hanger.






23. Position a suitable jack stand under the extension housing.






24. Remove the six transfer case-to-transmission bolts and separate the transfer case from the transmission.
25. Lower the transfer case from the vehicle.






26. Remove the transfer case-to-transmission gasket and clean the mounting surfaces.