Removal

Transfer Case Removal

1. Remove the rear driveshaft. Service and Repair






2. Remove the skid plate if equipped.






3. Index-mark the front axle pinion flange and the front driveshaft.






4. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.






5. Remove and discard the bolts and washers.






6. Remove and discard the bolts and universal joint retainers.

7. CAUTION: Always disconnect the front driveshaft from the axle first. Carefully pull the driveshaft out of the CV joint housing. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can cause the boot to tear.

CAUTION: Tape the bearing cups to the drive shaft to prevent them from falling off of the spider.

NOTE: The front driveshaft CV joint is not repairable.






^ Remove the driveshaft.






8. Drain the fluid if the transfer case is to be disassembled.






9. Disconnect the vent hose.







10. Positions suitable junk under the transmission.






11. Remove the LH heat shield-to-crossmember bolts.






12. Remove the RH heat shield-to-crossmember bolts.






13. Remove the two nuts nod the RH crossmember cover then remove the four crossmember bolts.






14. Remove the four LH crossmember bolts.






15. Remove the transmission mount nuts then remove the crossmember.
^ It may be necessary to pry the crossmember from the vehicle.






16. Remove the transmission mount.






17. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.






18. Lower the transmission jacks down just enough to access the upper transfer case-to-transmission bolts including the bolt retaining the fuel line bracket. Position the bracket out of the way.






19. Remove the remaining transfer case-to-transmission bolts. Separate the transfer cane from the transmission.






20. Remove the transfer case from the vehicle.
^ Move the transfer case rearward until the transfer case clears the output shaft. Lower and at the same time slightly tilt the rear of the transfer case downward.






21. Remove and discard the transfer case-to-transmission gasket. Clean the transfer case and transmission mating surfaces.