Transfer Case Removal

Transfer Case - Navigator

For Integrated Wheel End (IWE) vacuum disconnect procedures, refer to Drive Axles, Bearings and Joints/Axle Shaft Assembly/Front Axle Halfshafts. Service and Repair

1. With the vehicle in NEUTRAL position the vehicle on a hoist.

2. Drain the fluid if the transfer case is to be disassembled.
^ Install the drain plug when finished draining.

3. NOTE: The catalytic converter is removed for clarity.

Remove the transfer case-to-transmission brace.
1 Remove the bolts from the transmission.
2 Remove the nuts from the transfer case.





4. Remove the two nuts and the front driveshaft shield.

5. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.

Remove the front driveshaft.

6. NOTE: Index-mark the driveshaft to maintain initial driveshaft balance during installation.

Remove the rear driveshaft.





7. Disconnect the electrical connector.





8. Disconnect the vent hose.





9. NOTE: One transfer case-to-brace nut is located at the top of the transfer case input flange.

Remove the three transfer case-to-brace nuts.





10. Remove the stud.





11. Remove the transmission-to-brace nuts.





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

Using a suitable jack stand, support the transmission.

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

Using a suitable transmission jack, support the transfer case.





14. Remove the two exhaust heat shield-to-crossmember bolts.





15. Remove the bolt and the exhaust hanger bracket.





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

Remove the six transfer case-to-transmission extension housing bolts.
17. NOTE: Watch for obstructions.

Separate the transfer case from the transmission extension housing, move the transfer case rearward off the output shaft, then lower the transfer case from the vehicle.





18. CAUTION: Carefully clean the gasket surfaces. Nicks and gouges cause fluid leaks.

Remove the transfer case-to-transmission gasket and clean the mating surfaces.