Transfer Case-Removal
Removal1. Disconnect the battery.
2. Drain the transfer case.
3. Remove the driveshaft.
4. Remove the 4 bolts and the crossmember brace.
5. Remove the generator.
6. Disconnect the RH catalyst monitor.
7. Remove and discard the 2 nuts and separate the flexible Y-pipe from the manifold.
8. Remove and discard the nuts.
^ Discard the gasket.
9. Remove and discard the nuts.
^ Discard the gasket.
10. Remove the flexible pipe.
^ Disconnect the hanger.
11. Disconnect the EGR valve to exhaust manifold tube at the manifold.
12. Disconnect the RH heated oxygen sensor (HO2S).
13. Remove the RH exhaust manifold.
^ Discard the gasket.
14. Remove the bracket.
1. Remove the five bolts.
2. Loosen the bolt.
3. Remove the bracket.
15. Remove the 3 bolts.
16. CAUTION: The transfer case driven gear seal must be replaced whenever the linkshaft or transfer case is removed from the vehicle.
NOTE: If necessary, replace the RH differential fluid seal.
Remove the bolt and the transfer case.