For 1990-2009 cars

Table 1: | Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal
Table 2: | Intermediate Drive Shaft Removal
Table 3: | Rear Output Shaft Housing Removal
Table 4: | Right Transfer Case, Input and Output Drive Shaft Removal
Table 5: | Rear Output Shaft Housing Disassembly
Table 6: | Intermediate Drive Shaft Disassembly

### Housing O-Ring, Vent Assembly, Drain and Fill Plug Removal

Callout | Component Name
--- | ---
1 | Transfer Case O-Ring Seal
2 | Transfer Case Vent Assembly Tip Remove the vent only if damaged or blocked.
3 | Transfer Case Drain Plug
4 | Transfer Case Fill Plug

### Intermediate Drive Shaft Removal

Callout | Component Name
--- | ---
1 | Front Wheel Drive Retainer
2 | Front Wheel Drive Intermediate Shaft

#### Special Tools

J 25070 Heat Gun - 500-750F

For equivalent regional tools, refer to Special Tools.

### Rear Output Shaft Housing Removal

Callout | Component Name
--- | ---
1 | Transfer Case Rear Output Shaft Housing Bolt (Qty: 6)
2 | Transfer Case Rear Output Shaft Housing Tip Locate 2 screwdrivers or prybars to the flange area of the housing to ease removal.

#### Special Tools

J 25070 Heat Gun - 500-750F

3 | Transfer Case Rear Output Shim
4 | Transfer Case Rear Output Shaft Housing Seal O-Ring Tip Discard the O-ring after removal.

### Right Transfer Case, Input and Output Drive Shaft Removal

Callout | Component Name
--- | ---
1 | Transfer Case Half Bolt (Qty: 11)
2 | Transfer Case - Right
3 | Transfer Case Seal
4 | Transfer Case Input Shaft
5 | Transfer Case Rear Output Drive Shaft
6 | Transfer Case Half Locating Pin (Qty: 2) Refer to Transfer Case Cleaning and Inspection. Tip

• | Remove the pins only if damaged.

• | Inspect the case for similar damage.

### Rear Output Shaft Housing Disassembly

Callout | Component Name
--- | ---
1 | Transfer Case Rear Output Shaft Gear Nut Tip Use a 30 mm socket or J 29873 .

#### Special Tools

J-08614-A Pinion Flange Holder and Remover

2 | Transfer Case Rear Output Shaft Flange

#### Special Tools

DT-48145 Press Support

3 | Transfer Case Rear Output Shaft Bearing Assembly Tip Use a press to remove the output shaft from the housing.
4 | Transfer Case Rear Output Shaft Bearing Spacer
5 | Transfer Case Rear Output Shaft
6 | Transfer Case Rear Output Shaft Oil Slinger Refer to Rear Output Drive Housing Cleaning and Inspection. Tip Remove the slinger only if damaged.
7 | Transfer Case Rear Output Shaft Seal Tip Discard the seal after removal.

### Intermediate Drive Shaft Disassembly

Callout | Component Name
--- | ---
1 | Half Shaft Retainer
2 | O-Ring
3 | Front Wheel Drive Intermediate Shaft Bearing Retainer (Qty: 2)
4 | Front Wheel Drive Intermediate Shaft Bearing Assembly Tip Use a press, with the J 22912-B flat side up, in order to remove the bearing assembly.

#### Special Tools

J 22912-B Rear Pinion and Axle Bearing Remover