I guess I'll add to this thread.
I've got a pan on it's way for my 03 4wd with 70K, and am planning to do the swap this coming weekend.
Are there any parts that I can pretty much count on destroying and needing replacing? Special nuts/bolts, cotter pins, hoses/lines, seals/gaskets?
It looks like it is recommended to skip the oil pan gasket and just use RTV? Is CV grease ok to use for the hubs? Looks like they need to be disassembled, and some fresh grease won't ever hurt.
I'm going through the OEM service manual reading the procedure. Are there any special tools I should need? I have impact sockets (to 24mm), impact gun, jacks and stands, wrenches (up to 22mm), regular 1/2" sockets up to 21, plus 1", 1-1/4" 30mm and 32mm. I also have snap ring pliers, and a decent torch. I'm going to pick up a can of PB blaster, and start soaking everything. I do not have an engine hoist.
Once you have the front diff and cross member out of the way, do you need to lift the engine? Does the transmission need to be dropped? The manual shows to remove the rear trans-to-engine mounting bolts. It also looks like I shouldn't actually have to remove the front diff, just disconnect the front axles and lower it down?
I know, a bunch of questions, but I haven't ever had to work on this thing, it's been nice and reliable aside from this leak, and just want to know what to expect. I start a new job on Monday, pan should be here Friday/Saturday, so I'd like to get everything in order before hand so this will go as smoothly as possible. Thanks!