Overall, the transfer case is easy. Unless your like me, and prone to everything going wrong...

You may run into the u-joints being corroded to the rear axle yoke or the transfer cases front driveshaft yoke. You will either have to hammer them out, or pry them out. Just be prepared to replace them.
Note that for the rear driveshaft, it slides right out of the transfer case, so all you will need to do is disconnect from the rear axle and slide it out (in case you didn't know)

Getting to the top most trans to t-case bolt can be a pain.
And hopefully, for your sake, your transfer case isn't stuck to your transmission like mine was. (I had removed the trans/t-case for a trans change, and it took a sledge hammer to seperate from the trans!!)

 

Ok, I know I am going to sound like a complete newb here, but what is everyone using for transfer case fluid? I dont know how to check it or where to top it off at :S I honestly have never checked it and thats probably why I am having the issues I am having now.

 

Someone just asked this question. The post should be a few down. It has a good picture of the transfer case fill bolt and drain bolt. It is a 88 but same transfer case.

 

Use the exact same fluid you have in your transmission. I used Castrol ATF+4 last time I changed fluid in both the trans and transfer case.

 

Walmart used to sell MOPAR brand transmission fluid. Now they only sell the super tech +4 tranny fluid. Does anybody have any advise for or against using the supertech +4 in the transfer case?

 

Well I am happy to report that the old transfer case is out. And the new one is in! As I carried the old one away I could hear something rolling around in side so I know thats definitely not good. I put the salvage yard TC in and dispite its appearance and although I did have to sand off some surface rust on the clean metal surfaces, it seems to be in great shape. It shifts so smoothly that I couldnt tell if it had enagaged or not while rolling in a straight line. Had to do some sharper turns and inclined driving to make sure.

I decided to go with Valvolines ATF+4 full synthetic, mainly cause it was the only none house brand stuff I could find that wasnt going to bend me over the customer service desk.