Transfer case removal

[Strieg]

How do I separate the trans case from the back of the the transmission? Other than just the bolts. What do I need to keep mind of? As in gear positioning or anything like that?

 

[88_Eddie]

it'll have a clear rtv type sealant on it from the factory, so it'll be kinda tricky to get loose

i stuck a pry bar in mine and loosened it up a little bit. once it's pulled back a little, it'll swing down at almost a 90* angle from when it was bolted up. then just pull it back off the end of the transmission.

and it's gonna be heavy, especially if it's full of ATF. i get a buddy to help if you can.

doesnt have to be in a specific gear

 

[crawlin91]

if its a manual you will have to pull the shifter as well. remove all bolts connecting the two, speedo cable, wires etc. then use a combination of some careful prying(not on the mating surfaces), pulling and a rubber mallet to free the tcase up.

 

[Strieg]

It is a manual, and I already pulled the whole trans for a front seal/torque converter/trans filter replacement. Ok so it swings down 90 degrees from how it was bolted up to the truck?
And I'm hoping it's not full of fluid, kinda think it's not after it barfed all the trans fluid at a stoplight.

 

[Strieg]

Hey just finished up yesterday. The trans case was full, all I did was undo the lower filler plug and drained all the fluid which made it alot lighter.
For anyone doing a transmission pull/ transfer case pull in the future... It's easiest to to remove the trans case first, after draining fluid, keeps the transmission from twisting around during removal. But, there is a gasket between the two, trans and trans case. I didn't replace mine it was still fine. But if you take yours apart and need a new gasket you might be SOL I couldn't find at any parts store. And I tried all of the ones in my town. Autozone, napa carquest, and kragens

 

[88_Eddie]

Hey just finished up yesterday. The trans case was full, all I did was undo the lower filler plug and drained all the fluid which made it alot lighter.
For anyone doing a transmission pull/ transfer case pull in the future... It's easiest to to remove the trans case first, after draining fluid, keeps the transmission from twisting around during removal. But, there is a gasket between the two, trans and trans case. I didn't replace mine it was still fine. But if you take yours apart and need a new gasket you might be SOL I couldn't find at any parts store. And I tried all of the ones in my town. Autozone, napa carquest, and kragens

^
jeff's bronco graveyard has them. i didnt even bother putting mine back in, just lathered it up good with rtv, no leaks yet

 

[Steeda04SVT]

It's kinda tight towards the top so how hard was it to get to the top bolts of the T'case?

 

[Toms01PSD]

They are kind of a pain in the ass to get at. I'm in the process of replacing my POS electric t-case for a manual right now. It was pretty easy on a lift when I replaced my transmission, not so much in my driveway!

 

[Steeda04SVT]

Yeah it was def easy when I was doing a tranny swap a few months ago. Gonna try it soon.

 

[threecaster]

I've got my 2000 ext cab up on stands. The top xfer case bolts were actually pretty easy to get to, but I used a 12" + 6" extension (plus wobbler) and used the air gun. All 5 bolts are lock-tite'd, so sticky to the last thread.

Now I cannot get the thing off. I've pried on the bottom part and actually manage a visible gap at the gasket, but *whew* - the thing is really stuck on there. Likely never been off since factory...

I've beat with mallet, wood stick and hammer, now trying to get a small jack horizontally between it and a firm place. I've got a floor jack and wood block under it. I've raised the transmission and xfer case up and down a couple of inches about 6 times, trying to get it to come loose.

Trying to be nice to it. I really want to stick a pry bar or mega screwdriver up into the small gap, but it would make the gasket surface AFU, so I know better....

I think it's still glued at the top of the mating surface...

 

[Spitfire1975]

Hey just finished up yesterday. The trans case was full, all I did was undo the lower filler plug and drained all the fluid which made it alot lighter.
For anyone doing a transmission pull/ transfer case pull in the future... It's easiest to to remove the trans case first, after draining fluid, keeps the transmission from twisting around during removal. But, there is a gasket between the two, trans and trans case. I didn't replace mine it was still fine. But if you take yours apart and need a new gasket you might be SOL I couldn't find at any parts store. And I tried all of the ones in my town. Autozone, napa carquest, and kragens

Dealerships carry them. Last time I messed with my transmission, I just bought a few of them. Less than $5 a piece, if I remember right.

 

[scotts90ranger]

since there is a DRAIN hole at the bottom of the gasket area (look close, you'll see it), don't worry about the gasket too much, I think it's more to keep the two from corroding together...

 

[adsm08]

since there is a DRAIN hole at the bottom of the gasket area (look close, you'll see it), don't worry about the gasket too much, I think it's more to keep the two from corroding together...

It is legitimately needed in some applications. The E4-OH NO and FM 145/6 tend to get fluid moving into the extension housing that will leak out if the gasket or some sort of sealer isn't there.

 

[scotts90ranger]

either way, a little silicone would be easier to find than a gasket, even if there is some fluid there it won't be much...

 

[93bushtruck]

Im going to be doing this on my 93 with the auto trans, and will fluid spill everywhere out of the t-case/tranny when I seperate the 2?