Removal

REMOVAL

1. With the vehicle in neutral, raise and support the vehicle.





2. Remove the skid plate.





3. Remove the damper, if so equipped.





4. Disconnect the transfer case harness connector and position it aside.





5. If transfer case disassembly is necessary, remove the drain plug and drain the fluid.
^ Install the drain plug when all of the fluid has drained.





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

CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot between the shaft and the boot can and cause the boot to tear.

Disconnect the front driveshaft from the transfer case and position the driveshaft aside.
1. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
2. Remove and discard the bolts and washers.
3. Disconnect the front driveshaft from the transfer case and position the driveshaft aside.

7. CAUTION: Index-mark the front flange on the rear driveshaft and the flange on the transfer case.

Remove the rear driveshaft.

8. WARNING: Secure the transfer case to the jack with safety straps.

Position a high lift jack under the transfer case.





9. Remove the transfer case from the vehicle.
1. Remove the five bolts retaining the transfer case to the extension housing.
2. Slide the transfer case rearward and off of the transmission output shaft.
3. Remove and discard the front extension housing gasket, and clean the mating surfaces.