Removal Procedure

WARNING: This page is about a different variant/trim than selected.

Place the air system in service mode.
Place the transmission in neutral service mode. Neutral Service Mode
Disconnect the battery negative cable. Battery Negative Cable Disconnection and Connection (9C1, 5W4) , or Battery Negative Cable Disconnection and Connection (KL9)
Front Wheelhouse Liner - Left Side and Right Side - Remove - Front Wheelhouse Liner Replacement
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Evaporative Emission Canister Bracket Nut (1) - Loosen [2x]
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Evaporative Emission Canister Bracket Bolt (1) - Remove
Evaporative Emission Hose (2) - Disconnect [3x] - Plastic Collar Quick Connect Fitting Service
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Evaporative Emission Canister (1) - Remove
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Unclip the 2 air line retainers (1) and reposition the air line (2).
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If equipped, remove the chassis wire harness clip (1) from the automatic level control air supply reservoir.
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Remove the 3 automatic level control air compressor bolts (1).
Automatic Level Control Air Supply Reservoir (2) - Reposition
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Drain the fluid from the transfer case. Transfer Case Fluid Replacement
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Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 2 - Disconnect
Using a suitable tool, remove the heated oxygen sensor bank 1 sensor 2 (1).
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Transfer Case Front Output Shaft Boot Clamp (1) @ Front Axle Propeller Shaft - Remove and DISCARD
Reposition the transfer case front output shaft boot (2) and mark a reference point between the front axle propeller shaft and the transfer case front output shaft.
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Mark a reference point between the front axle propeller shaft (1) and the front differential drive pinion gear yoke.
Front Axle Propeller Shaft Bolt (2) - Remove [6x]
Front Axle Propeller Shaft Washer (3) - Remove [3x]
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Front Axle Propeller Shaft (1) - Remove
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Transfer Case Front Output Shaft Boot Clamp (2) @ Transfer Case - Remove and DISCARD
Transfer Case Front Output Shaft Boot (1) - Remove
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Mark the relationship of the propeller shaft to the differential drive pinion gear yoke.
Rear Propeller Shaft Bolt (1) - Remove [4x]
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Propeller Shaft (1) - Remove
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Exhaust Heat Shield Bolt (1) - Remove
Exhaust Front Pipe Heat Shield (2) - Remove
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Exhaust Heat Shield Bolt (1) - Remove
Exhaust Front Pipe Heat Shield (2) - Remove
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CAUTION:
Refer to Heated Oxygen and Oxygen Sensor Caution .
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.
- The heated oxygen sensor MAY be difficult to remove when the engine temperature is less than 48°C (120°F).
Electrical Connector @ Heated Oxygen Sensor Bank 1 Sensor 1 - Disconnect
Remove the heated oxygen sensor bank 1 sensor 1 (1) using a suitable tool.
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Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 1 - Disconnect
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Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 2 - Disconnect
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Exhaust Pipe Clamp (1) - Loosen
Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) - Separate
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Exhaust Front Pipe Nut (1) - Left Side - Remove [3x]
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Exhaust Front Pipe Nut (1) - Right Side - Remove [3x]
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{If equipped} Remove the wiring harness (2) from the 3 wiring harness retainers (1) and reposition the wiring harness as necessary.
Support the transmission with a suitable jack.
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Transmission Mount Nut (1) - Remove [2x]
Transmission Support Crossmember Nut (2) - Remove [4x]
Transmission Support Crossmember Bolt (3) - Remove [4x]
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Transmission Support Crossmember (1) - Remove
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Three-Way Catalytic Converter (1) - Remove
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Exhaust System Seal - Left Side (1) - Remove and DISCARD
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Exhaust System Seal - Right Side (1) - Remove and DISCARD
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Disconnect the transmission wiring harness retainer (1) and reposition the harness as necessary.
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Transmission Heat Shield Bolt (2) - Remove
Transmission Heat Shield Bolt (1) - Remove [2x]
Transmission Heat Shield (3) - Remove
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Transmission Mount Bolt (1) - Remove [2x]
Transmission Mount (2) - Remove
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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).
Remove the wiring harness retainer (3) from the transfer case and position the wiring harness out of the way.
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Transfer Case Vent Hose (1) - Remove
Using a suitable transmission jack, support the transfer case.
Using suitable straps or chains, secure the transfer case to the transmission jack.
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Transfer Case Nut (1) - Remove [6x]
Transfer Case (2) - Remove
Transfer Case Adapter Gasket (3) - Remove and DISCARD