I did some hunting around and couldn't find much conversation around pulling the transfer case. I'm pretty certain my transfer case chain is slipping. I've acquired one from a salvage yard and was looking for anyone with experience performing the swap.

From what I can tell, I will remove the drive shafts, then the 8 bolts attaching the t-case to the transmission. It appears I'll need a special tool for some of these bolts. Just getting underneath it, they seem impossible to get to. Perhaps I'll have to come down from inside the truck?

Anyhow, any insight would be appreciated!

 

I don't think you need the special tool, but you do need a stubby socket or something like that if I remember right...

Take a look through the thread below. It doesn't directly answer your question, but lots of good info and pictures.
Magna Steyr DD295 Transfer Box Teardown

 

I have removed 4 and installed 2.

I suggest stubby box end watching wrench(I think those are 13mm) and torque adaptor. Use a long extension and go at the hardest to get bolt from behind the t case above.

These are the torque adaptors:

 

What makes you think it is slipping? What are the symptoms? I mean I know what a slipping tranny feels like. How is a slipping T-Case similar?

 

The slipping transfer case is actually the chain jumping teeth. When accelerating and under load, the chain jumps. It's a pretty scary pop, pop, pop when it jumps.

 

So you remove the console come from inside the truck up top? Also, do I need to remove the exhaust and transmission cross member?

 

Ahhhh.....right, the "clank clank clank" is reminiscent of my brother's old '75 Ford that had T-Case issues. Is it only in certain Terrain Response settings? Do you have the HD package? My slipping (locking) rear diff clutches made a similar sound.

 

All work from the bottom. Look in Tom's tech section at the top for how to Trans service. There is a video on how to service which shows removing the t case support and the exhaust.

So remove:
- t case support
- exhaust- video uses heat, I soak bolts in deep creep for 10 minutes
- both driveshafts
- disconnect all wires to t case
- remove 13mm bolts to divorce t case from Trans.

The torque adaptor will help with one or two of the hard ones at the top. As I said you will be underneath but going at them from the back of the t case on top of it.

Good luck. You can call me if you have any questions. My number is in my signature.