For 1990-2009 cars

1. Remove the rear extension housing bolts.
2. Tap the extension housing with a rubber mallet in order to free it from the sealer.

Remove the rear extension housing.

3. Remove the rear bearing retainer snap ring from the mainshaft.
4. Remove the rear retainer housing bolts.

Important: Do not pry against the sealing surfaces of the rear retainer or the rear case. Only pry under the tabs on the retainer housing.

5. Carefully pry upward under each tab on the retainer housing.

Remove the rear retainer housing from the rear case half.

6. Remove the snap ring in front of the speedometer tone wheel from the mainshaft.
7. Remove the speedometer tone wheel from the mainshaft.
8. Remove the snap ring behind the speedometer tone wheel from the mainshaft.

Important: Some transfer case models have a bracket attached to them by the case half bolts. These bolts are different from the others and must be put back into the correct holes.

9. Remove the case bolts from the case halves.

The two longer case bolts and washers go into the doweled case holes.

Important: The oil pump is located in the rear case half. Do not damage the oil pump while removing the rear case half.

10. Separate the case halves by inserting two screwdrivers into the slots cast into the case ends.

Pry the case halves apart.

Do not attempt to wedge the case halves apart at any point on the mating surfaces. Damage to the case may result.

11. Remove the rear case half and the oil pump as an assembly from the front case.
12. Remove the two dowels from the case halves.