Removal Procedure
Air Cleaner Bolt (1) - Remove
- Evaporative Emission Canister Purge Tube (2) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Positive Crankcase Ventilation Tube (3) - Disconnect - Plastic Collar Quick Connect Fitting Service
- Electrical Connector (4) - Disconnect [2x]
Air Cleaner Outlet Duct Clamp (1) - Loosen
- Wiring Harness Retainer (2) @ Air Cleaner Assembly - Remove [4x]
- Engine Wiring Harness (3) - Reposition
Remove the air cleaner (1) and air cleaner outlet duct (2) as an assembly.
- Disconnect and reposition the heated oxygen sensor electrical connector as necessary.
- CAUTION:
Refer to Heated Oxygen and Oxygen Sensor Caution .
CAUTION:The use of excessive force may damage the threads in the exhaust manifold/pipe.
NOTE:The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
NOTE:The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield Bolt (1) - Remove [2x]
Turbocharger Heat Shield (1) - Remove
- Raise and support the vehicle. Lifting and Jacking the Vehicle
- Disconnect and reposition the heated oxygen sensor electrical connector as necessary.
- Using the EN-6179 Heated Oxygen Sensor Remover/Installer, remove the heated oxygen sensor (1).
- Drain the fluid from the transfer case. Transfer Case Fluid Replacement
Floor Panel Number 4 Cross Bar Reinforcement Bolt (1) - Remove [6x]
- Floor Panel Reinforcement (2) - Remove
Catalytic Converter Nut (1) - Remove [2x]
Electrical Connector (1) @ Exhaust Control Valve Actuator - Disconnect [2x]
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Left Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Left Side (3) - Separate
Exhaust Muffler (1) @ Exhaust Intermediate Pipe Insulator-Right Side (2) - Separate
- Exhaust Muffler (1) @ Exhaust Rear Muffler Insulator-Right Side (3) - Separate
{ If equipped } Front Crossmember Brace Nut (1) - Remove [4x]
- { If equipped } Front Crossmember Brace (2) - Remove
Exhaust Muffler (1) - Remove
- Catalytic Converter Gasket (2) - Remove and DISCARD
Exhaust Pipe Clamp (1) - Loosen
Catalytic Converter Brace Bracket Nut (1) - Remove [2x]
- Catalytic Converter Brace Bolt (2) - Remove [2x]
- Catalytic Converter Brace (3) - Remove
Warm Up Three-Way Catalytic Converter (1) - Remove
- Exhaust Pipe Clamp (2) - Remove and DISCARD
- Catalytic Converter Gasket (3) - Remove and DISCARD
Front Axle Propeller Shaft Heat Shield Bolt (1) - Remove [2x]
- Front Axle Propeller Shaft Heat Shield Stud (2) - Remove
- Front Axle Propeller Shaft Heat Shield (3) - Remove
- Support the transmission with an appropriate jack.
Transmission Mount Bracket Bolt (1) - Remove [4x]
- NOTE:
The transmission mount bolt is retained in the mount, loosen the bolt to disengage the threads and remove the mount and bolt as an assembly.
Transmission Mount Bolt (1) - Remove
- Transmission Mount (2) - Remove
Transfer Case Front Output Shaft Boot Clamp (1) @ Transfer Case Front Output Shaft - Remove and DISCARD
- Release the transfer case front output shaft boot (2) from the groove in the transfer case front output shaft.
Mark the relationship between the front axle propeller shaft (2) and the front differential carrier flange with a grease pencil.
- Front Axle Propeller Shaft Bolt (1) - Remove [6x]
- Front Axle Propeller Shaft Washer (3) - Remove [3x]
Front Axle Propeller Shaft (1) - Remove
Inspect the transfer case front output shaft boot (1), if damage is found, remove and DISCARD the transfer case front output shaft boot clamp (2) and the transfer case front output shaft boot (1).
Rear Tire Front Air Deflector Bolt (1) - Remove [2x]
- Rear Tire Front Air Deflector- Left Side (2) - Remove
Rear Wheelhouse Liner Screw (1) - Remove
- Underbody Rear Air Deflector Plastic Nut (2) - Remove [3x]
- Underbody Rear Air Deflector Bolt (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Left Side (5) - Remove
Rear Tire Front Air Deflector Bolt (2) - Remove [2x]
- Rear Tire Front Air Deflector- Right Side (1) - Remove
Rear Wheelhouse Liner Screw (1) - Remove
- Underbody Rear Air Deflector Bolt (2) - Remove [3x]
- Underbody Rear Air Deflector Plastic Nut (3) - Remove [3x]
- Underbody Rear Air Deflector Nut (4) - Remove [2x]
- Underbody Rear Air Deflector- Right Side (5) - Remove
Propeller Shaft Hub Clamp (1) - Remove and DISCARD
Mark (2) the relationship of the propeller shaft to the rear differential flange using a paint pen.
- Rear Propeller Shaft Nut (3) - Remove [3x]
- Rear Propeller Shaft Bolt (1) - Remove [3x]
- Support and secure the propeller shaft to a suitable hydraulic jack stand.
Propeller Shaft Bearing Support Bolt (1) - Remove [2x]
Propeller Shaft (1) - Remove
- Support the transmission with a suitable jack.
Disconnect the electrical connectors. (1)
- Wiring Harness Retainer (2) - Remove [2x]
Electronic Transmission Range Selector Manual Park Release Cable Clamp Bolt (1) - Remove
- Electronic Transmission Range Selector Manual Park Release Cable (2) @ Transmission - Remove
Unclip the electronic transmission range selector manual park release cable (1) retainer from the electronic transmission range selector manual park release cable bracket.
- Remove the electronic transmission range selector manual park release cable (2) from the transmission.
- Using the jack, lower the transmission enough to access the transfer case fasteners.
- Using a suitable transmission jack, support the transfer case.
- Using suitable straps or chains, secure the transfer case to the transmission jack.
Transfer Case Nut (1) - Remove [2x]
Transfer Case Stud (1) - Remove [4x]
- Transfer Case Assembly (2) - Remove
In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Avoid contact with HOT components. Wear safety glasses and protective gloves to avoid personal injury.
The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
The heated oxygen sensor in-line connector and louvered end MUST be kept clear of all grease, dirt, and other contaminants. Do NOT use cleaning solvents of any type. Do NOT drop or roughly handle the sensor.
When removing the propeller shaft, do not remove the propeller shaft coupler from the propeller shaft assembly. The only bolts that should be removed are those that mount each coupler to the transmission output flange, and to the rear drive axle input flange. Failure to properly remove the propeller shaft assembly may cause coupler damage, resulting in necessary replacement of the entire propeller shaft.