Transfer Case: Removal
- Disconnect negative battery cable. Remove both front and rear console boxes. On 4WD models, remove gear shift control lever knob, boot cover, lever boot and case boot. Remove gear shift control lever from gear shift lever case by pushing down and turning counterclockwise 1/4 turn, then pulling up.
- Disconnect both 4WD electrical harness connectors. On all models, remove 4 bolts from radiator fan shroud. Raise and support vehicle. Remove transfer case skid plate. Drain transaxle oil. On 4WD models, place an index mark on front drive shaft flange and yoke for installation reference. Remove front drive shaft.
- On all models, place an index mark on rear drive shaft flange and yoke for installation reference. Remove rear drive shaft. Disconnect speedometer cable. Remove one bolt, speedometer cable clip and ground wire from torque stopper housing. Remove Three-Way Catalytic Converter (TWC) and muffler/tailpipe assembly.
- Support transfer case with jack. Remove 2 bolts from torque stopper bracket, and 6 bolts from transfer case crossmember. Remove crossmember. Place a wood block (1.8" x 5" x 8") between distributor gear housing and bulkhead to prevent damage to components while lowering transfer case.
- Slowly lower transfer case. Remove breather hoses from gear shift lever case and cover (if equipped). On models equipped with manual transmission, remove gear shift lever case from rear of transmission. Remove 12 transfer case-to-transmission bolts. Separate transfer case from transmission, lower and remove from vehicle.