The Factory Service Manual says to remove the drive shaft from the transfer case before removing the pan.  Looks to me like this isn't absolutely necessary, that the pan could be snaked out of there without removing the shaft. Is this possible, or just wishful thinking?

Not really necessary but just makes it a little easier when you try to drain the fluid as the pan drops.

Looks like you just drop the one end, not both.  Is that correct? I can see how this might avoid an ATF bath.

If you figure out how to drop the pan WITHOUT getting an atf bath, I'd like to know.

drill a 1/8" hole where you can see the ridges as if it had a drain plug.

drain

remove pan and install a drain plug where you drilled hole = no mess

drill a 1/8" hole where you can see the ridges as if it had a drain plug.

drain

remove pan and install a drain plug where you drilled hole = no mess

That's about what I did.

drill a 1/8" hole where you can see the ridges as if it had a drain plug.

drain

remove pan and install a drain plug where you drilled hole = no mess

Any leakage after putting in the drain plug?

I can't speak for him but mine was a bit over 3 years after the install when I sold it.  No leaks or troubles.

No leakage around plug so far. I did add RTV around its gasket just in case.

Quote from: ecoast on June 02, 2011, 04:01:04 AM

drill a 1/8" hole where you can see the ridges as if it had a drain plug.

drain

remove pan and install a drain plug where you drilled hole = no mess

Any leakage after putting in the drain plug?

no; teflon washers on bung (came with assembly, 5/6 bucks at napa)