Hey Mike, are you considering the kit? Here are a few tips.
^Get a LR mannual, It helps you with the removal of case. The Maxi instructions only deal with modifying case.
^My mannual said there were 4 bolts holding case to trans, but there are 6. a couple are hard to get at.
^Roller jack-I welded a angled adapter to bolt transfer to rollerjack. This will make removal effortless and minimize chance of damage to seal.
^I Left the truck on the garage floor, and that worked well with my creeper and reach.
^The nuts and bolts really piled up, so I started putting them in labeled ziplock bags.
^Be sure to drain case before you attach jack adapter, many of the transfer case bolts go through case.
^It is easier to remove and install case if you remove the gear/bearing cluster inside the PTO cover first.
^When you get case onto work bench you need to remove the entire emer brake housing and the front difflock housing. Also you will remove all linkage coverplates etc.
^The center differential shaft and orig bullgear pull out easy through the large opening. The intermediary cluster also removes easy.
^A bottle jack hydrolic press makes removing old bull gear/clutches/and bearings easy.
^I followed the directions for the grinding. The directions stated that the new bull gear would sit just one millimeter below the widest point on the lip. But when I pressed the new gear in place, it rubbed on the lip. Not good so i ground the lip about 2mm ish.
^The new bull gear is larger than the portal, so it is assembled inside case. This is not to difficult, but extra hands would be nice.
^When re-installing all the parts back on case- use plenty of THE RIGHTSTUFF on mating surfaces, also pre think out where the sealer needs to be -to prevent leaks. Atleast half of the bolt holes go through and into case.
^The intermediary gear cluster just slips in and a shaft run through the middle. Save the PTO gear install until after the case is bolted back to transmission.
^The process of removing the case initially involves removing many parts, such as entire exhaust system; driveshafts; multiplugs and wires; shift linkages; E brake cable;
hi-low shifter and inside console; parts to fan cowling to allow lowering case to access areas above and behind case; 3rd link arm etc.
^ I was able to complete entire job solo with the use of the floor jack and adapter. The adapter can be made out of mild steel and bolts to the rectangular inspection plate beneath case.
^I change my gear oil 3 times in a short period to remove any alluminum or steel particles.
^full set of ratcheting box wrenches; 1/2-3/8drivesockets and extensions.