Transfer Case Replace

NEW PROCESS MODEL 205
1. Raise and support vehicle.
2. Drain transfer case, then disconnect speedometer cable, back-up light switch connector and TCS switch, if equipped.
3. Remove skid plate and crossmember supports, if necessary.
4. Disconnect front and rear propeller shafts from case and position aside.
5. Disconnect shift lever rod from shift rail link.
6. Support transfer case, then remove case to adapter attaching bolts.
7. Slide transfer case rearward until input shaft clears adapter and remove from vehicle.
8. Reverse procedure to install.

NEW PROCESS MODEL 208
1. Place transfer case shift lever in 4H position.
2. Raise and support vehicle, then drain transfer case.
3. Remove cotter pin from shift lever swivel.
4. Scribe alignment marks on front and rear output shaft yokes and propeller shafts to aid reassembly.
5. Disconnect speedometer cable and indicator switch wiring.
6. Disconnect propeller shafts from yokes.
7. Disconnect parking brake cable guide from right frame rail pivot, if necessary.
8. On automatic transmission equipped vehicles, disconnect engine strut rod from transfer case.
9. Support transfer case, then remove case to adapter attaching bolts.
10. Slide transfer case rearward until free of transmission output shaft and remove from vehicle. Remove gasket from adapter housing.
11. Reverse procedure to install using new gasket on adapter housing.