Removal

Transfer Case

Transfer Case

NOTE: Automatic transmission shown, manual transmission similar.











1. NOTE: Shift the transfer case to 2H.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Jacking and Lifting Service and Repair.

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. For additional information, refer to Driveshaft Removal and Replacement.

6. NOTICE: The front driveshaft must be disconnect the from the transfer case first. 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 CV-joint.

Disconnect the front driveshaft from the transfer case and position the driveshaft aside in the following sequence. 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 a strap.

9. Remove the 5 transfer case-to-transmission bolts.

10. Separate the transfer case from the extension housing. Pull the transfer case rearward and lower the transfer case from the vehicle.
- Remove and discard the gasket and clean the mating surfaces.