REMOVAL & INSTALLATION
See Figures 1 through 7
- Disconnect the negative battery cable.
- Shift the transfer case into the 4WD High range.
- Raise and support the vehicle safely using jackstands.
- Remove the transfer case shield bolts, then remove the shield from under the transfer case assembly.
- Remove the plug and drain the transfer case fluid.
- Matchmark and remove the front and rear driveshafts from the transfer case.
- Tag and disconnect the vacuum lines and/or the electrical connectors, as equipped.
- Disconnect the transfer case shift rod or cable from the case, if applicable.
- If applicable, remove the support brace-to-transfer case bolts.
- Support the transfer case using a floor jack, then remove the transfer case-to-transmission retaining bolts
- Slide the transfer case rearward and off the transmission output shaft, then careful lower it from the vehicle.
- Remove all traces of old gasket material from the mating surfaces.
- Installation is the reverse of removal, but please pay special attention to the following important steps.
- Using the floor jack, carefully raise the transfer case into position behind the transmission. Position a new gasket, using sealer to hold it in position, then slide the transfer case onto the transmission output shaft.
- Tighten the transfer case-to-transmission retaining bolts to 24 ft. lbs. (33 Nm) on 1994 vehicles, 41 ft. lbs. (55 Nm) on 1995-98 vehicles or 33-35 ft. lbs. (45-47 Nm) on 1999 models.
- If equipped, tighten the support brace bolts to 35 ft. lbs. (47 Nm) on 1994-95 vehicles, or 35-37 ft. lbs. (47-50 Nm) on 1996-99 vehicles.