Disconnect the ground cable from the negative battery terminal, by using a wrench to loosen the retaining bolt and pulling the clamp off the terminal. Raise the vehicle and support with jack stands placed underneath the frame. Drain the transfer case. Locate the drain plug near the bottom of the transfer case. Place a waste oil collection pan underneath the plug and use a socket to remove it. Once all the fluid has drained out, reinstall the plug. Remove the bolts that connect the rear driveshaft to the rear axle yoke using a socket. Lower the driveshaft, and slide it backward underneath the rear axle to disengage it from the transfer case. Remove it from the vehicle. Remove the bolts that connect the front driveshaft to the front axle yoke using a socket. Lower the driveshaft, and slide it forward underneath the front axle to disengage it from the transfer case. Remove the driveshaft from the vehicle. Label and disconnect the electrical wires and vacuum lines connected to the transfer case. Use masking tape and a marker. Remove the transfer case shifter rod. Using needle-nose pliers, remove the clip that connects the shifter rod to the transfer case. Slide the rod away from the transfer case. Position a floor jack underneath the transfer case. Raise it enough to take the weight of the transfer case off the transmission. Remove the bolts that connect the transfer case to the transmission using a socket or wrench. Slide the transfer case rearward to disengage it from the transfer case. Lower the floor jack, and remove the transfer case from the vehicle.
Removing the Transfer Case
SOURCE: removal of transfer case 1996 chevy tahoe
Fairly simple, 6 bolts, drive shafts,a few wires. Must go to the rear and then bring the front down and out
SOURCE: I need to remove the
It can be removed with out removeing the transmission however it is a lot of work . You say its a manual shift although there are still electrinci componuts involved as well as vacuum issues to be considered . You don't say what the problem you are experinaceing is . But cable adjustment also comes into play here I would do some home work before i started taring things down .You see it could be something much simpler like a vacuum hose or a loose wire or a cable adjustment . Form a game play first it could save you a lot of wasted time and money
SOURCE: We have a 1996 Chevy Tahoe. the actuator on the transfer case bad
you can remove acuator buy turning it out like a light bulb.use a channel lock pliers.
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