I'm replacing a leaky rear output seal and transfer case input shaft seal on my 99 2dr w/ 2.5L ax-5 five speed np-231. Never had the t-case off and wondering if any one has advice or could point me in the direction of a write-up on how to disconnect the linkage on the t-case. and if there are any special tools that I would need for the seals..... besides the basic seal removal tool.
Anything would help, did a lot of searching around and found a bunch of people asking the same type of question but didn't have any real solid answers.

 

After removing the crossmember and supporting the transmission, remove the breather, speedo gear wire, 4wd detector light wire, and the linkage. The linkage is just one nut holding it then it slides right off. As far as unbolting the t/c from the transmission, get some shorty wrenches, I hear they work well. Or just do what I do and get a long 12"+ extension and air ratchet to loosen up the six nuts holding the transfercase to the transmission. Then the t/c will come right off and weighs about 90 lbs. Pretty simple in theory, but it takes some maneuvering to figure out how to reach those nuts. Lowering the transmission as low as you can helps make some more clearance up there.

Pretty easy overall, just some tight spots.

 

I did my 84 years ago, in the rain/mud. No fun, but just straight forward wrenching.

 

Not sure on the seals, but I've done 2 NP231 swaps now and I found *several* extensions and a u-joint were best to get at the bolts up top. You may also unhook the exhaust from the hangers to get more room (at least on the 4.0) but don't need to.