Removal

Transfer Case - 4.4L

Service Repair No - 41.20.25.99

Special Service Tools





Removal
1. Disconnect the battery ground cable.

WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

2. Raise and support the vehicle.
3. Remove the transmission support crossmember.
4. Remove the rear driveshaft.


CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.

CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

5. Release the front driveshaft from the transfer case drive flange.
^ Remove the 6 Torx bolts and washers, discard the bolts.





6. Remove the transmission support insulator.
^ Remove the 5 bolts.





7. Disconnect the transfer case 3 electrical connectors.





CAUTION: Always plug any open connections to prevent contamination.

8. Disconnect the breather line.
^ Depress the locking ring.





9. Support the transmission on a jack.

WARNING: Secure the component to the transmission jack.

10. Using a transmission jack, support the transfer case.
11. With assistance, remove the transfer case.
^ Remove the 8 bolts.
^ Remove the O-ring seal.