Removal
Transfer CaseTransfer Case - With Automatic Transmission (Part 1):
Transfer Case - With Automatic Transmission (Part 2):
Transfer Case - With Manual Transmission (Part 1):
Transfer Case - With Manual Transmission (Part 2):
1. NOTE: Shift the transfer case to 2H.
With the vehicle in NEUTRAL, position it on a hoist.
2. Remove the 4 skid plate bolts and the skid plate.
3. Disconnect the transfer case electrical connector and position it aside.
4. If disassembly is necessary, drain the fluid. Install the drain plug when finished.
5. NOTE: Index-mark the front flange on the rear driveshaft and the flange on the transfer case.
Remove the rear driveshaft.
6. CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft may pinch the boot between the shaft and the boot, and cause the boot to tear.
NOTE: Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.
Disconnect the front driveshaft from the transfer case and position the driveshaft aside. Using mechanic's wire, support the driveshaft.
1 Index-mark the front output shaft assembly to the front driveshaft CV joint.
2 Remove and discard the 6 front driveshaft-to-CV joint bolts and retainers.
3 Disconnect the front driveshaft.
7. Disconnect the vent hose.
8. Position a suitable high-lift jack to the transfer case and secure it with safety straps.
9. Remove the 5 transfer case-to-transmission bolts.
10. Separate the transfer case from the extension housing. Pull the transfer case rearward, then lower the transfer case from the vehicle.
^ Remove and discard the gasket and clean the mating surfaces.