Removal
REMOVAL / NV231 Transfer Case1. Shift transfer case into NEUTRAL.
2. Raise vehicle.
3. Remove skid plate.
4. Drain transfer case lubricant.
5. Mark front and rear propeller shaft yokes for alignment reference.
6. Disconnect front/rear propeller shafts at transfer case.
7. Disconnect transfer case position sensor connector.
8. Disconnect transfer case shift cable at the range lever.
9. Disconnect the transfer case shift cable from the shift cable bracket.
10. Disconnect transfer case vent hose.
11. Support transfer case with transmission jack.
12. Secure transfer case to jack with chains.
13. Remove nuts attaching transfer case to transmission.
14. Pull transfer case and jack rearward to disengage transfer case.
15. Remove transfer case from under vehicle.
REMOVAL / Transfer Case Position Sensor
1. Raise and support the vehicle.
2. Disengage the transfer case position sensor connector from the position sensor.
3. Remove the position sensor from the transfer case.
REMOVAL / Shift Lever
1. Shift transfer case into 4L.
2. Raise vehicle.
3. Remove clip securing the transfer case shift cable to the shift cable support bracket.
4. Disengage any additional shift cable routing clips, if necessary.
5. Disengage the shift cable from the transfer case manual lever.
6. Lower vehicle.
7. Remove the floor console as necessary to access the shifter mechanism.
8. Remove the nuts attaching lever assembly to floor pan and remove assembly and shift cable.
9. Remove the shifter mechanism and cable assembly from the vehicle.
REMOVAL / Front Output Shaft Seal
1. Raise vehicle.
2. Remove front propeller shaft.
3. Remove front output shaft companion flange.
4. Remove seal from front case with pry tool.
REMOVAL / Rear Output Shaft Seal
1. Shift the transmission and transfer case into NEUTRAL.
2. Raise and support vehicle.
3. Mark a line across the pinion shaft and at each end of the propeller shaft for installation reference.
4. Remove the U joint strap bolts at the pinion shaft yoke.
5. Pry open clamp holding the dust boot to propeller shaft yoke.
6. Slide the slip yoke off of the transmission/transfer case output shaft and remove the propeller shaft.
7. Spread band clamp, which holds output shaft boot to the output shaft slinger, or output shaft damper, with a suitable awl, or equivalent.
NOTE: Vehicles built with a manual transmission use a damper weight on the transfer case output shaft. Be sure to identify the transfer case before proceeding.
8. Remove output shaft boot from slinger, or output shaft damper, and output shaft.
9. If the vehicle is not equipped with an output shaft damper, remove the output shaft rear slinger using Puller MD-998056-A.
10. If the vehicle is equipped with an output shaft damper, use Screws 8421 and the puller yoke and forcing screw from a bolt-grip puller set, such as those used to remove steering wheels and harmonic balancers, to remove the transfer case output shaft damper.
11. Use a suitable pry tool, or a slide hammer mounted screw, to remove the seal from the rear retainer.