Removal

Special Tools:

Special Tool(s)

1. WARNING: The electrical power to the air suspension system must be shut of[prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the RH kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.

Raise and support the vehicle.





2. Remove the transfer case skid plate.
1 Remove the four bolts (two each side).
2 Remove the transfer case skid plate.





3. NOTE: Drain the transfer case if disassembly is necessary.

Drain the transfer case.
^ Install the drain plug when finished draining.





4. NOTE: Index-mark the rear driveshaft yoke and pinion flange to maintain initial driveshaft balance during installation.

Remove the rear driveshaft.
5. Remove the torsion bars and rear torsion bar support.





6. CAUTION: Never support the transmission from the bottom of the transmission pan.

Support the transmission.





7. Remove the two exhaust heat shield-to-cross member bolts (one each side).





8. Loosen, but do not remove the transmission mount-to-cross member nuts.





9. Remove the six cross member-to-frame nuts and bolts (three each side).





10. Remove the transmission mount-to-cross member nuts, and remove the cross member.





11. Remove the transmission mount and the exhaust hanger.





12. Remove the front driveshaft shield.
1 Remove the nuts.
2 Remove the front driveshaft shield.





13. NOTE: Index-mark the front driveshaft yoke and flange to maintain driveshaft balance during installation.

Disconnect the front driveshaft at the transfer case.





14. Disconnect the electrical connector.





15. CAUTION: Secure the transfer case to the jack with a safety strap.

Using a hi-lift jack, support the transfer case.





16. CAUTION: Position a suitable drain pan below the transmission extension housing.

Remove the six transfer case-to-transmission extension housing bolts (three each side).

17. CAUTION: Watch for obstructions.

Separate the transfer case from the transmission extension housing and lower the transfer case.