Transfer Case - Manual Transmission
Transfer Case - Manual Transmission1. Raise and support the vehicle.
2. Drain the fluid if the transfer case is to be disassembled.
3. Remove the four bolts and the skid plate.
4. NOTE: Index-mark the driveshaft yoke to the rear axle flange and to the transfer case flange.
Remove the rear driveshaft.
5. NOTE: Index-mark the driveshaft yoke to the transfer case flange and to the front axle flange.
Remove the front driveshaft.
6. Disconnect the motor electrical connector.
7. Disconnect the vent hose.
8. Using a suitable jack, support the transmission.
9. Remove the RH and LH side heat shield-to-crossmember bolts.
10. Remove the two nuts and the RH crossmember cover, then remove the four crossmember bolts.
11. Remove the four LH crossmember bolts.
12. Remove the transmission mount nuts, then remove the crossmember.
^ It may be necessary to pry the crossmember from the vehicle.
13. Remove the transmission mount.
14. Position a suitable transmission jack to the transfer case. Securely strap the transfer case to the jack.
15. Remove the seven transfer case to transmission bolts. Separate the transfer case from the transmission.
16. 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.
17. Remove and discard the transfer case to transmission gasket. Clean the transfer case and transmission mating surfaces.