911 - Help Please with Transfer Case Removal!!!!

wizkid00104 · Nov 23, 2007

My transfer case is stuck. I took out all 5 bolts and wd-40 soaked everything. I have removed everything needed to take the case out. My dad and I banged, wedged, pried, and smacked at the damn thing for 2 and a half hours and it is still stuck. We then strapped a tow strap around the case and to the back of my dad's ranger and pulled and jerked and for god's sakes and it is still seized.

I am soo frustrated. Please help!

metalmacguyver · Nov 23, 2007

remove tranny with it and put it on the bench. then try working at it from all sides.

wizkid00104 · Nov 23, 2007

I can get at it from all sides where it is, and it is my daily driver. Do you have any idea what siezed it?

4x4RangerGuy · Nov 23, 2007

Nothing else should be holding it on to the transmission except the output shaft. Usually with enough work it will break free. Sounds like yours is on there really tight.

Have you heated the flanges up? I've had to do that on my t-case before to get things to start breaking apart. Just be careful not to heat it up too much, it's only aluminum/magnesium.

wizkid00104 · Nov 23, 2007

What did you use to heat it? I was working in about 32 degrees today. I just want to be careful because of my fuel tank.

kunar · Nov 23, 2007

are you sure you got all the bolts?? (not calling you stupid or anything, just double check) i have never had mine stick like that before. once its unbolted, all that holds it on is the gasket sealer.

wizkid00104 · Nov 23, 2007

I know. There were 5 bolts and the alignment pin. I got the speedocable and both drive shafts. I have no idea what is keeping it sooooo tight.

surffishin07 · Nov 24, 2007

you might have a busted or slipped spline in the output shaft of the transmission i had a buddy with a full size bronco that we got so pissed we droped the tranny still couldnt get it so we used the cuttin torch to see the prob and the tranny and t-case splines had stripped and welded togather. Do you put it under enought stress to do anything like that??

4x4RangerGuy · Nov 24, 2007

I just used an acetyline torch to heat up the flange, and it came right off.

Like surffishin said, if the shafts are stuck together, you might need to get a cutting torch and cut the damn thing off. Try heating it with an acetyline torch first to see if it will break it apart.

wizkid00104 · Nov 24, 2007

I drove it on the highway and rarely take it offroad because the damn electronic shift is so unreliable.

Jspafford · Nov 24, 2007

When that happens it is usually the alignment pin seized. Pulling it with a towstrap will not do much because it won't be pulling straight on it. You need a very thin wedge to put in there and work it loose.

Oh and before you get too wild with it I would loosely thread 2 of the bolts back in. That way you don't have to worry about it coming loose and falling off when you least expect it.

wizkid00104 · Nov 24, 2007

There is only 5 bolts going front to back and none threaded the other way right?

wizkid00104 · Nov 24, 2007

Will heating the alignment pin help?

AllanD · Nov 24, 2007

Yes, all five bolts are "head forward"

That and the alignment pin are all that hold it on.

yes, sometimes the splines "Stick",

what I usually do to seperate the two is to use two "screwdriver handled"
prybars back to back and try the case off, you've just gotta keep working at it.

when you do get them seperated grease the splines.

AD

wizkid00104 · Nov 24, 2007

I got it, it was the stupid alignment pin. I heated it up with propane and it came right apart. Thanks Everyone!!!

911 - Help Please with Transfer Case Removal!!!!

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