Transfer Case Removal 4WD

Applies directly to our truck — the transfer case is a shared 4WD component independent of whether the main transmission is manual or (as on our truck) the 3A/T.

Preparation

• Remove Front Driveshaft.
• Disconnect Speedometer Cable (4WD).
• Remove Center Exhaust Pipe.

Transfer case removal

The source list mixes sequential removal steps with exploded-diagram component labels; order is preserved as printed.

1. Remove Transfer Case Shifter Assembly.
2. Remove Cross Member retainer bolts and support case with a jack.
3. Washer Cups.
4. Spacer — inspect for damage and replace as necessary.
5. Mount “A” — replace if cracked or damaged.
6. Remove Cross Member and mounting brackets.
7. Mount Cushions — inspect for cracking or damage, replace as necessary.
8. Transfer Mount Bracket (LH).
9. Transfer Mount Bracket (RH).
10. Vibration Mounts.
11. Remove Transfer Case.
12. Inspect Transfer Cross Member.
13. Installation in reverse.

Torque

Torque callout	N·m (kgf·m)
T=22 (16 ft-lb)	(2.2)
T=19 (168 in-lb)	(1.9)
T=19 (168 in-lb)	(1.9)
T=22 (16 ft-lb)	(2.2)
T=19 (168 in-lb)	(1.9)
T=22 (16 ft-lb)	(2.2)
T=44 (32 ft-lb)	(1.4)

(verify printed p.175) — the last callout, transcribed by OCR as T=44 (1.4), is internally inconsistent: 44 N·m does not convert to 1.4 kgf·m (it should read roughly 4.5 kgf·m, matching the pattern used elsewhere in this chapter, e.g. T=44 (4.5) in Transmission Removal). This is very likely an OCR error on one side of the pair — possibly T=44 (4.5) or T=14 (1.4) — but the correct value is not confirmed. Do not use either guess without checking the printed diagram.