lary was brimming with questions about the xj. i gave him a feiw sugestions.
lets see what i can dig up real fast for ya biglary!
Torx via "The Nail Salon"
With the front end basically done, I moved onto the transfer case. Goal was to yard it out from the Jeep, and install the AA SYE and Teraflex 2Low. The install can be done with it under the vehicle. I've done them both ways, and prefer to pull them. It's only six extra bolts, and gives you plenty of work space.
I started by draining the fluid. It was was definitely due for a change, and smelled horrible.
Pulled the rear drive line. Late models use these goofy boots on the slip yoke, which need to be removed to pull the shaft.
Disconnect the linkage at the transfer case, 9/16 nut.
Working around my old manual trans was a breeze compared to the automatic and all the junk that goes along with it. After the sensors, linkage, and vent hose are disconnected from the transfer case, remove the tranny to t-case nuts. There's six toal, and they're a 9/16. The very bottom one was completely blocked by the tranny mount, so off came the cross member and mount.
Gotta get creative.
Eventually the case was out from the vehicle.
I started to tear into the case, but broke my cheap set of snap ring pliers on the first snap ring (they lasted through a few t-case tear downs so I can't complain too bad). I tracked down a loaner set for the next day, and put the t-case project on hold.
Tracked down my loaner set of snap ring pliers. These are pretty trick, and make snap ring removal/install a breeze.
I began disassembling the case. For the most part the 97+ cases are like the earlier models. The biggest difference is in the tail housing. Early models are a breeze to remove, late models have about a dozen parts holding it on.
First thing that had to go was a pressed on "slinger" on the tail shaft. AA recommends using a long two jaw puller. I chose the die-grinder method. Since I wouldn't be reusing these parts, I took a cut off wheel and slowly cut away the pressed on sleeve part to relieve the stress. Then I took a chisel and "peeled" away the sleeve. At this point I could remove it by hand.
Beneath the slinger I found another pressed on retainer. I'm sure there's another tool for this, but I used a pry bar to walk it off.
Beneath that I found an external snap ring.
With the snap ring removed the tail housing still wouldn't budge. So I continued to dig deeper. Out came the seal (I wouldn't be reusing this).
Not surprising, I found another snap ring under the seal (you'll want to remove the external one on the shaft).