Transfer Case Removal

Transfer Case

Special Service Tools






Wrench adaptor

303-1069

Removal
1 Disconnect the battery ground cable. For additional information, refer to Specifications Service and Repair
2
WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.
Raise and support the vehicle.




3 Remove the transmission heat shield.
- Remove the 4 bolts.




4 Remove the ground cable from the transfer box.
- Remove the bolt.
5 Remove the transmission crossmember. For additional information, refer to Transmission Support Crossmember - 5.0L NA V8 - AJ133 Service and Repair




6
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.
Release the front driveshaft from the transfer case drive flange.
- Remove the 6 Torx bolts and washers, discard the bolts.
- Using a suitable tie strap, reposition and secure the driveshaft to the exhaust system.




7 Remove the fuel tank heat shield.
- Remove the 3 bolts and 2 nuts.




8
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.
Release the rear driveshaft from the transfer case drive flange.
- Remove the 6 Torx bolts and washers.




9
CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.
Release the driveshaft center bearing mount.
- Remove the 2 driveshaft center bearing mount bolts.
- Using suitable securing strap, reposition and support the driveshaft.





10 Disconnect the transfer case 3 electrical connectors.





11 Release the wiring harness from the transfer case.
- Remove the 3 bolts.
- Release the clip.





12
CAUTION: Always plug any open connections to prevent contamination.
Disconnect the breather line.
- Depress the locking ring.





13 Release the fuel line support bracket.
- Remove the 3 bolts.

14 Support the transmission on a jack.

15
WARNING: Secure the component to the transmission jack.
Using a transmission jack, support the transfer case.





16 With assistance, remove the transfer case.
- Remove the 8 bolts.
- Move the fuel hose support bracket aside.
- Remove the O-ring seal.