Removal Procedure
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.
Refer to Safety Glasses Warning .
- 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
Evaporative Emission Canister Bracket Nut (1) - Loosen [2x]
Evaporative Emission Canister Bracket Bolt (1) - Remove
- Evaporative Emission Hose (2) - Disconnect [3x] - Plastic Collar Quick Connect Fitting Service
Evaporative Emission Canister (1) - Remove
- Drain the fluid from the transfer case. Transfer Case Fluid Replacement
- 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 2 - Disconnect
- Using a suitable tool, remove the heated oxygen sensor bank 1 sensor 2 (1).
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.
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]
Front Axle Propeller Shaft (1) - Remove
Transfer Case Front Output Shaft Boot Clamp (2) @ Transfer Case - Remove and DISCARD
- Transfer Case Front Output Shaft Boot (1) - Remove
Mark the relationship between the propeller shaft and the differential drive pinion gear yoke using a suitable tool.
- Rear Propeller Shaft Bolt (1) - Remove [4x]
Propeller Shaft (1) - Remove
Exhaust Heat Shield Bolt (1) - Remove
- Exhaust Front Pipe Heat Shield (2) - Remove
Exhaust Heat Shield Bolt (1) - Remove
- Exhaust Front Pipe Heat Shield (2) - Remove
- 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
- Using a suitable tool, remove the heated oxygen sensor bank 1 sensor 1 (1)
Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 1 - Disconnect
Electrical Connector @ Heated Oxygen Sensor Bank 2 Sensor 2 - Disconnect
Exhaust Pipe Clamp (1) - Loosen
- Exhaust Muffler (2) @ Three-Way Catalytic Converter (3) - Separate
Exhaust Front Pipe Nut (1) - Left Side - Remove [3x]
Exhaust Front Pipe Nut (1) - Right Side - Remove [3x]
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.
Transmission Mount Nut (1) - Remove [2x]
- Transmission Support Crossmember Nut (2) - Remove [4x]
- Transmission Support Crossmember Bolt (3) - Remove [4x]
Transmission Support Crossmember (1) - Remove
Three-Way Catalytic Converter (1) - Remove
Exhaust System Seal (1) - Left Side - Remove and DISCARD
Exhaust System Seal (1) - Right Side - Remove and DISCARD
Disconnect the transmission wiring harness retainer (1) and reposition the harness as necessary.
Transmission Heat Shield Bolt (2) - Remove
- Transmission Heat Shield Bolt (1) - Remove [2x]
- Transmission Heat Shield (3) - Remove
Transmission Mount Bolt (1) - Remove [2x]
- Transmission Mount (2) - Remove
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 retainer (3) from the transfer case and position the wiring harness out of the way.
Transfer Case Nut (1) - Remove [3x]
- Transfer Case Vent Hose (2) - Disconnect
- 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 [3x]
- Transfer Case (2) - Remove
- Transfer Case Adapter Gasket (3) - Remove and DISCARD
Refer to Heated Oxygen and Oxygen Sensor Caution .