Removal And Installation: Notes

REMOVAL 

1. Raise and support vehicle. Refer to HOISTING, STANDARD PROCEDURE .
2. If equipped, remove the skid plate. Refer to PLATE, SKID, REMOVAL AND INSTALLATION and/or PLATE, SKID, TRANSFER CASE, REMOVAL AND INSTALLATION .
3. Position a drain pan underneath the transfer case.
4. Remove the transfer case drain plug and drain the lubricant into the drain pan.
5. Remove the front and rear propeller shafts. Refer to REMOVAL AND INSTALLATION - AXLE SHAFTS, DRIVE SHAFTS AND HALF SHAFTS .

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   1 - Wire Harness Connector

6. Disconnect the wire harness connector from the shift motor.

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   1 - Vent Tube

   2 - Wire Harness Connector

7. Remove the vent tube and the wire harness connector from the neutral safety switch.

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   1 - Transfer Case Shift Cable

   2 - Shift Rod

8. Disconnect the transfer case shift cable and the shift rod.

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   1 - Two Bolts

   2 - Nut

9. Remove the two bolts and one nut securing the transfer case shift bracket to the transmission housing.

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   1 - Transfer Case Shift Bracket

10. Remove the transfer case shift bracket.
11. Using a suitable jack stand, support the transmission.
12. Remove the transfer case crossmember. Refer to CROSSMEMBER, TRANSMISSION, REMOVAL AND INSTALLATION and/or CROSSMEMBER, FRONT REINFORCEMENT, REMOVAL AND INSTALLATION .

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    1 - Shift Cable Retaining Bracket Nut

13. Remove the shift cable retaining bracket nut, then remove the shift cable retaining bracket.
14. Using a suitable jack, support the transfer case. Using safety chains, secure transfer case to the jack.

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    1 - Transfer Case Bolts

    NOTE:

    There are seven bolts securing the transfer case to the transmission.

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    1 - Transfer Case Bolts

15. Remove the seven bolts securing the transfer case to the transmission assembly.

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    1 - Transfer Case Shift Bracket

    2 - Transfer Case Shift Bracket Bolts

16. Remove the transfer case shift bracket from the top of the transfer case.
17. Move the transfer case assembly rearward until it is free of the transmission output shaft.
18. Lower the jack and remove the transfer case from under the vehicle.

INSTALLATION 

Follow the removal procedure in reverse for general reassembly of the components on the vehicle. The steps listed below are calling out specific procedures that should be followed during installation.

• Fill the transfer case with the specified fluid. Refer to CAPACITIES AND RECOMMENDED FLUIDS .