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how do you change a transfer case?

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Old May 6, 2010 | 09:32 PM
  #11  
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r6roadracer
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I did mine this past winter and it was straightforward:

1. Remove rear driveshaft
2. Remove skid plate
3. Support transmission with jack
4. Remove transmission mount and remove crossmember (way easier with it out)
5. Remove front driveshaft
6. Remove vacuum lines for CAD vacuum switch on tcase
7. Remove speedometer electrical connector
8. Disconnect shift linkage - easiest to just take nut off shift arm on tcase
9. Lower jack to get tail of trans as low as possible
10. Remove 6 nuts on front of tcase where mates to trans - leave two on at end
11. Break tcase-tranny mating surface apart and slide tcase back a little bit, maybe an inch tops
12. Remove the two remaining nuts while supporting t case so it doesnt slide back and land on your head
13. Slide tcase off until it comes off input shaft and lower to ground. It weighs about 75 lbs. I was able to do this without a jack and while lying on my back. It has some weight to it, but it is doable.

Reverse.
 
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