Removal Procedure
- Start vehicle and shift the transfer case to 2WD/2High.
- Turn the vehicle off.
- Disconnect the battery negative cable. 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 and reposition the harness as necessary.
.Transfer Case Two/Four Wheel Drive Actuator Sensor Bolt (1) - Remove [4x]
- Transfer Case Two/Four Wheel Drive Actuator (2) - Remove
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
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
Drill a pilot hole in the body of the transfer case input shaft seal (1).
- Insert a self-tapping screw into the transfer case input shaft seal (1).
- Using pliers or slide hammer type tool, remove and DISCARD the transfer case input shaft seal (1).
Do NOT use a pry tool to remove the transfer case input shaft seal (1).