GM 91173105 Rear Half Transfer Case

To perform the removal of the transfer case in models of Samurai the first step is to snap off the battery's negative terminal to prevent any accidental short-circuit and the next step is to safely lift the car on the help of jackstands. Separate the speedometer cable, shift lever and the 4 WD switch and then, drain the lubricants from the transfer case and transmission. Don't forget to take out the driveshafts and any part of the exhaust system that would come into the way. Place a floor jack under it to keep it off the ground whenever the transfer case is out will be useful. Place support under transfer case through the use of floor jack and then engage the safety chains. Disconnect the nuts and bolts holding the rear of the transfer case to the crossmember, lift the transfer case vertically slightly and pull off the crossmember. Ensure that all the wires and hoses are disconnected to ensure that you do not have a problem when moving the transfer case and jack to the back of the car. Take off the intermediate shaft in conjunction with the transfer case and lower them away from the car. For further installation, place the transfer case to the jack and raise it to the position behind the transmission and then maneuver it forward until the intermediate shaft comes into contact. Fit and tighten the crossmember and the transmission support and finally remove the jacks. Replace all the items that have been removed in the process; make sure all the wires, hoses and the speedometer cable are connected; ensure that the transmission and the transfer case are filled with the lubricant. Last, attach the last negative cable terminal, and take a road-test to assess the proper functionality of the car and to check for leakage. For Sidekick/X-90/Vitara and Tracker models, this should be done with the key out of the ignition, negator cable disconnected, center console and the shift levers for the transmission and transfer case loosened. Check out the removal steps of the transfer case as well as the gear shift lever case and the transfer case center bolt and transfer case-to-transmission fastenings. Place the transfer case assembly on a jack and then move it backward as much as possible and remove the jack. For installation, just bolt the transfer case upside down to the jack, properly position it at the back of the transmission, adjust the splines correctly before tightening the transmission to transfer case bolts. Proceed to the last procedures where you are to reinstall the software and test it.

During disassembly, it is crucial to take careful notes on the arrangement and placement of each piece, as this will facilitate reassembly.