Remove

Service tools: 18G1425 - Guide studs(3). Also, locally manufactured adaptor plate, see below.








Adaptor Plate For Removing Transfer Gearbox
The transfer case should be removed from underneath the vehicle, using a suitable transmission jack. An adaptor plate for locating the transfer case onto the jack can be manufactured locally.

REMOVE
1. Install the vehicle on a suitable hoist.
2. Open the hood.
3. Disconnect the battery.
4. Release the airflow meter to plenum chamber hose.
5. Remove the four screws securing the glove box liner to the glove box and lift out the liner.





6. Carefully pry the window lift switch panel away from the front of the glove box.
7. Identify each switch connection for re-assembly, disconnect the plugs and remove the switch panel.
8. Remove the transmission and transfer case knobs.
9. Carefully pry the center panel out of the floor mounted console and remove it from the vehicle.





10. Release the two bolts and two screws securing the console assembly to the gearbox tunnel.
11. Release the parking brake and remove the cotter pin, clevis pin and washer securing the parking brake cable to the parking brake lever.
12. Carefully maneuver the assembly away from the radio housing and remove it from the vehicle.
13. Release the large nut retaining the parking brake outer cable to the top of the gearbox tunnel.
14. Remove the nut and feed the cable through the hole to the underside of the vehicle.





15. Raise the vehicle on the hoist and drain the transfer case.
16. Release the nut and clamp securing the speedometer cable to the rear of the transfer box.
17. Withdraw the cable from the speedometer drive pinion.
18. Release the four nuts securing the rear drive shaft to the rear output flange and tie to one side of the chassis.
19. Remove the four nuts securing the front drive shaft to the front output flange and tie to one side of the chassis.
20. Release the bolts securing the intermediate exhaust pipe to the center catalyst and separate the pipes. Retrieve the doughnut.
21. Remove the clamp at the tailpipe bracket, carefully tie the exhaust to the chassis side member.
22. Manufacture an adaptor plate in accordance with the drawing, to attach to the transmission jack and transfer box to facilitate removal.
23. Place four 30 mm (1.250 in) long spacers between the top of the hoist and the adaptor plate at the securing points and secure the adaptor plate to the hoist.
24. Remove the four central bolts from the transfer box bottom cover, move the jack into position and secure the adaptor plate to the transfer box.
25. Adjust the jack to take the weight of the transfer box.
26 Remove the tie bar from the transfer case.
27. Remove the right-hand side mounting bracket to chassis nuts and bolts.
28. Remove the rear left-hand side mounting bracket to chassis nuts and bolts.
29. Remove right-hand side mounting bracket to flexible mounting rubber retaining nut and place bracket aside.
30. Lower the jack until the rear brake drum clears the rear passenger footwell.
31. Remove the cotter pin and washers securing the differential lock lever to the connecting rod, and disconnect the lever from the rod.
32. Disconnect the electrical leads from the differential lock switch and neutral warning switch.
33. Remove the breather pipe from the top of the transfer case.
34. Select low range transfer box gear position.
35. Release the high/low rod lower lock nut and remove the rod from the yoke.
36. Place a suitable wooden block between the main gearbox and chassis cross-member, then lower the jack until the gearbox contacts the wooden block.
37. Remove the upper and lower bolts securing the transfer box to the main gearbox.
38. Fit three guide studs to the main gearbox 18G1425 and maneuver the transfer case rearwards to detach it from the main gearbox.