Removal Procedure

TRANSFER CASE ASSEMBLY REMOVAL

REMOVE OR DISCONNECT
1. Negative (-) battery cable.
2. Two screws, two plastic retainers and rear console box from floor.
3. Two screws, two plastic retainers and front console box from floor.





4. One screw and gearshift control lever knob from gearshift control lever (if equipped).





5. Eight screws, boot cover and gearshift control lever boot from gearshift control lever (if equipped).
6. One clamp and gearshift lever case boot from gearshift lever case (if equipped).





7. Gearshift control lever from gearshift lever case by pushing down on the gearshift control lever pivot and turning counterclockwise 90° (1/4 turn) and lifting up (if equipped).





8. Four-wheel drive switch electrical connector from four wheel drive switch (if equipped).





9. Four-wheel drive low switch electrical connector from four-wheel drive low switch (if equipped).
10. Four bolts from fan shroud at radiator.
11. Raise and suitably support vehicle.





12. Two bolts and separate transfer case skid plate from transfer case crossmember.
13. Place a drain pan or suitable container underneath transfer case.





14. Transfer case oil level/filler plug from transfer case.
15. Transfer case drain plug from transfer case and drain transfer case oil.

Important: An index mark (reference mark) should be made on the front and rear propeller shaft pinion flange yokes and the front and rear differential pinion flanges to ensure that the front and rear propeller shafts are installed in the same positions from which they where removed. If this precaution is not observed, a driveline imbalance may result causing vibration, premature component wear or other undesirable conditions.

16. Place an index mark on the front propeller shaft pinion flange yoke and the front differential pinion flange (if equipped).
17. Four bolts, four nuts And front propeller shaft from vehicle (if equipped).
18. Place an index mark on the rear propeller shaft pinion flange yoke and the differential pinion flange.
19. Four bolts, four nuts and rear propeller shaft from vehicle.





20. Speedometer cable from speedometer driven gear case.





21. One bolt, speedometer cable clip and ground wire from torque stopper housing.
22. Three Way Catalytic Converter (TWC) and muffler/tail pipe assembly from vehicle.
23. Support transfer case with a suitable hydraulic jack.





24. Two bolts from torque stopper bracket.





25. Six bolts and transfer case crossmember from undercarriage.





26. Place a wood block with the dimensions shown between the distributor gear housing and the bulkhead to prevent the distributor and other components from being damaged when the transfer case is lowered.
27. Lower transfer case slowly until engine contacts its support point on the wood block.
28. One clamp and breather hose from gearshift lever case (if equipped).
29. One clamp and breather hose from cover (if equipped).
30. Gearshift lever case from rear case manual transmission equipped vehicles.
31. Twelve transfer case-to-transmission bolts.
32. Slide transfer case off transmission output shaft and slowly lower transfer case making sure there are no obstructions.

Inspect
- For disassembly and inspection procedures, refer to TRANSFER CASE UNIT REPAIR.