Transfer Case: Service and Repair

1. Disconnect battery ground cable, then raise and support vehicle and drain transfer case oil.
2. Disconnect front and rear propeller shaft as outlined under "All Wheel Drive.
3. Support transmission with appropriate stand, then remove lower transmission crossmember and transmission mount.
4. Support transfer case with appropriate stand.
5. Remove upper transmission mount, then exhaust system.
6. Disconnect odometer cable, then electrical connectors.
7. Remove bolts from transfer case to transmission, Fig. 1, then gently separate transfer case from transmission by tapping lightly with plastic hammer. Lower transfer case.
8. Reverse procedure to install noting the following:
a. Ensure sealing surfaces are clean and dry.
b. Apply silicone sealant to transfer case before installation.

Fig. 1 Transfer Case Replacement: