Removal

Removal

WARNING: The electrical power supply 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 rear jack storage 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.

1. With the transmission in neutral, raise and support the vehicle.





2. Remove the skid plate.





3. Note: Drain the fluid if disassembly is necessary.
Remove the drain plug and drain the fluid.
- Install the drain plug when finished draining.





4. Index-mark the rear output flange and the driveshaft yoke.





5. Remove the four bolts.





6. Separate the driveshaft from the output flange, and position the driveshaft aside.





7. Index-mark the lower output assembly and the front driveshaft.





8. Remove and discard the bolts and straps.





9. Separate the driveshaft from the lower output assembly, and position the driveshaft aside.





10. CAUTION: Never support the transmission from the bottom of the transmission pan.

Support the transmission.





11. CAUTION: Secure the transfer case to the jack with a safety strap.

Support the transfer case with a suitable hi-lift jack.





12. Remove the nuts.





13. Remove the crossmember.
1. Remove the two bolts and nuts at each end of the crossmember.
2. Remove the bolt, nut and spacer at each end of the crossmember.
3. Remove the crossmember.





14. Remove the transmission mount.





15. Disconnect the vent tube.








16. CAUTION: Position a suitable drain pan below the transmission extension housing.

Remove the five accessible bolts.





17. Remove the six bolts.





18. Separate the extension housing and transfer case assembly from the transmission case.





19. Separate the extension housing from the transfer case.
1. Remove the remaining bolt.
2. Separate the extension housing from the transfer case.





20. CAUTION: Watch for obstructions.

Lower the jack and the transfer case.





21. Remove the extension housing.
22. Remove and discard the transfer case-to-extension housing gasket, and the transmission-to-extension housing gasket. Clean the gasket surfaces.