Removal Procedure
- Start vehicle and shift the transfer case to 2WD/2High.
- Turn the vehicle off.
- Remove the negative battery cable from the battery. Battery Negative Cable Disconnection and Connection (without K4B)Battery Negative Cable Disconnection and Connection (with K4B)
Drain the fluid from the transfer case. Transfer Case Fluid Replacement
Disconnect the transfer case two/four wheel drive actuator electrical connector (1).
- Disconnect the transfer case two/four wheel drive actuator position sensor electrical connector (2).
- Disconnect the wiring harness retainers from the transfer case and position the wiring harness out of the way.
Front Axle Propeller Shaft Slip Yoke Boot Clamp (1) @Front Axle Propeller Shaft - Remove and DISCARD
- CAUTION:
When removing the propeller shaft, do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint. If the propeller shaft is removed by using such means, this may lead to premature failure of the joint.
Mark a reference point between the front axle propeller shaft and the front axle drive pinion flange.
- Front Axle Propeller Shaft Bolt (2) - Remove [4x]
- Front Axle Propeller Shaft Retainer (1) - Remove [2x]
Front Axle Propeller Shaft (1) - Remove
Front Axle Propeller Shaft Slip Yoke Boot Clamp (2) - Remove and DISCARD
- Front Axle Propeller Shaft Slip Yoke Boot (1) - Remove
Disconnect the vent hose (1) from the transfer case.
Mark the relationship of the propeller shaft (2) to the rear wheel drive shaft flange.
- Rear Propeller Shaft Bolt (1) - Remove [4x]
Propeller Shaft (1) - Remove
- Support the transmission with a suitable jack.
Transmission Mount Nut (1) - Remove [2x]
Transmission Support Crossmember Nut (2) - Remove [4x]
- Transmission Support Crossmember Bolt (1) - Remove [4x]
Transmission Support Crossmember (1) - Remove
Transmission Mount Bolt (2) - Remove and DISCARD [2x]
- Transmission Mount Heat Shield (1) - Remove
- Transmission Mount (3) - Remove and DISCARD
- 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 [8x]
- Lower the transfer case (2) out of the vehicle.
- Transfer Case Adapter Gasket (3) - Remove and DISCARD