Replacing my t-case (snapped chain) today , also have a 4 button and I was wondering about the fluid level required after install . Good info. While I was pulling it out today I ran into a problem and also after a little scratching my head a solution . Tale of transfer case was getting wedged on the torsion support bar and the body without enough clearance to exit the tail shaft of the transmission . I remember seeing a video earlier in the week of a guy that had a 2 inch body lift could slide the transfer case right out without any trouble . So after reinstalling the transfer case , I used a bottle jack and 4 x 4 to lift the floor up inch and a half or so allowing the clearance for the tale of the transfer case. Tomorrow I am going to attempt for installation of the used transfer case . I did have almost 2 quarts of tranny fluid in the collar between the transmission and transfer case , the collar ( 6bolt on the trans side & 5 bolt on the transfer case side ) . Is that normal?

 

I just swapped my TCase and had ran across a tip about pulling the trans/engine forward about 1/2 inch making a big difference. I used some nylon bike tie down straps and a racheting winch (come a long) and rigged up a wooden jig to help with final lift and getting bolts started. It all worked great.

 

I'm pretty sure there should not be transmission fluid between the transmission and the transfer case. If there is, then you will need to replace the seal on the transmission output shaft.