Desparate 98 t-case removal

[DC2]

Can anyone verify beyond a shadow of doubt that a transfer case for a 98 3.0 v6 4x4, 5 speed manual transmission with the electronic shift motor is connected to the rear of the transmission by only 5 bolts? Been trying to pry the thing off for days now with no luck. Got frustrated and attempted to use a jack to break the seal but it started to lift the entire truck...stopped before any damage was done, but seems to me that such a force should break the seal somehow.

Researched a bit more...someone else had the same problem...heated the alignment pin with a torch and it separated. Trying to find images to locate the pin but no luck. Where is the pin located?

 

[enjr44]

Not me!! But, they seem to be all the same.

http://www.autozone.com/repairguide...ase-Removal-Installation/_/P-0996b43f8036de2d

And, of course, by now you should be completely familiar with everything in this section

http://www.therangerstation.com/tech_library/index-transmission-transfer-case.shtml

 

[adsm08]

I have seen many t-cases that needed the swing press to get them off the trans. There are only 5 bolts. The gasket has 6 holes, one is for the pin.

Heating the area should help, but care needs to be taken if using acetylene because the trans and t-case cases are aluminum. It won't take much to ruin them.

 

[RonD]

You can see the pin in a few pictures here: http://www.therangerstation.com/Magazine/spring07/BW1350_1354_doubler.shtml

It is opposite side from front driveshaft, approx. mid-line.
In the first pic you can see a little rusting thing sticking out, that would be the alignment pin/dowel

 

[willy]

Come along it back then hit it with a soft hammer to pop it free

 

[jeremysdad]

Or, lacking a dead blow...3 pound sledge, hold the head in your hand, and flat palm it with the handle.

Don't lock your wrist. But don't limp wrist either. Recommend eye protection. Everytime you hit something while looking up under an older vehicle, you'll get an eye full of *something.

Still giggling @ 'swing press'.

 

[jeremysdad]

Hate my s6. Stupid smart phone.

 

[DC2]

Thanks for all the replies...truly appreciated! Going to heat the alignment pin with a propane torch and pull the thing off with a come along. Will let you know how it goes. Thanks again!

 

[AllanD]

All the T-cases are "light alloy" but not all light alloy is aluminum...

I've seen several that were "Alu-Mag" alloy
and I have one around here somewhere that has a case marked "Mg"

Be afraid, be VERY afraid of turning a torch on a MAGNESIUM transfer-case housing...

I strongly recommend reaming the dowel hole in the transmission extension housing and giving the inside of it a good coat of paint and/or smearing it liberally with Never-seeze
or some good synthetic marine rated grease...

There is a reason many factory T-case mounting bolts have a heavy black oxide coating and are fitted with Special aluminum anti-corrosion washers...