Removal

Transfer Case - 4.4L

Service Repair No - 41.20.25.99

Special Service Tools:

Removal

1. Disconnect the battery ground cable.

2. WARNING: Do not work on or under a vehicle supported only by a jack. Always support the vehicle on safety stands.

Raise and support the vehicle.
3. Remove the transmission support crossmember.
4. Remove the rear driveshaft.

5. CAUTION: Mark the position of the driveshaft flange in relation to the drive pinion flange.

CAUTION: To avoid damage to the joint or gaiter, do not allow the driveshaft to hang.

Release the front driveshaft from the transfer case drive flange.
Remove the 6 Torx(R) bolts and washers, discard the bolts.





6. Remove the transmission support insulator.
Remove the 5 bolts.





7. Disconnect the transfer case 3 electrical connectors.





8. CAUTION: Always plug any open connections to prevent contamination.

Disconnect the breather line.
Depress the locking ring.





9. Support the transmission on a jack.

10. WARNING: Secure the component to the transmission jack.

Using a transmission jack, support the transfer case.
11. With assistance, remove the transfer case.
Remove the 8 bolts.
Remove the O-ring seal.