Removing The Transfer Case (TC)

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Maybe it’s possible to remove it from that end, but I didn’t do it that way as the worked that needed to be done on my tcase necessitated the replacement of all the seals and required me to tear it down. Here is an image of the interior. You’ll notice that there is no inner retaining ridge, so you would want to take care not to push it in to far or crooked.

IMG_9025.webp
 
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Adsing said:
Maybe it’s possible to remove it from that end, but I didn’t do it that way as the worked that needed to be done on my tcase necessitated the replacement of all the seals and required me to tear it down. Here is an image of the interior. You’ll notice that there is no inner retaining ridge, so you would want to take care not to push it in to far or crooked.

View attachment 4125247
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I got it out. Very small seal puller. Just be very careful not to score the edge.
 
HHR137 said:
Little bit but not bad.
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Please show us photos of the TM side, the removal of the retainer which is held in place by five bolts, the O-ring inside the retainer, and the oil seal replacement on the transmission output shaft! I'm looking forward to it!
 
lc80fzj said:
Please show us photos of the TM side, the removal of the retainer which is held in place by five bolts, the O-ring inside the retainer, and the oil seal replacement on the transmission output shaft! I'm looking forward to it!
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Dude I am sorry, I already did it all. I’ll try and be as detailed in explaining it.

It’s 5 12mm bolts. They appear to all be the same size but I drew a diagram and numbered them just to make sure the same bolts when back in the same places.

Once the bolts are removed the flange is pretty tight. I tapped on the transmission with a hammer to help loosen it. I also used a seal puller very gently to break it free. Once free slide it off the outpost shaft. From there you can easily tap the seal out. There is also a rubber o ring on the back side of the flange. No idea what part # it is but I didn’t replace it. This part is incredibly simple. Just make sure you put the seal on evenly. It’s easy to get crooked.
 
HHR137 said:
Dude I am sorry, I already did it all. I’ll try and be as detailed in explaining it.

It’s 5 12mm bolts. They appear to all be the same size but I drew a diagram and numbered them just to make sure the same bolts when back in the same places.

Once the bolts are removed the flange is pretty tight. I tapped on the transmission with a hammer to help loosen it. I also used a seal puller very gently to break it free. Once free slide it off the outpost shaft. From there you can easily tap the seal out. There is also a rubber o ring on the back side of the flange. No idea what part # it is but I didn’t replace it. This part is incredibly simple. Just make sure you put the seal on evenly. It’s easy to get crooked.
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Thank you for the detailed explanation! Even without photos, I could easily imagine how you proceeded with the removal.
By the way, did you find out the tightening torque for the five bolts?
Also, did you use any threadlocker on the five bolts?
 
lc80fzj said:
Thank you for the detailed explanation! Even without photos, I could easily imagine how you proceeded with the removal.
By the way, did you find out the tightening torque for the five bolts?
Also, did you use any threadlocker on the five bolts?
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I don’t know the spec. I just put them back on snug. I didn’t use any loctite because there wasn’t any on them when I removed them.
 
This really needs to be in the FAQ; I have not found a published torque specification for the joint between the transmission and transfer case, in any 80 service manual. It is in the LX450 manual, however:
1776689049235.webp

The driveshaft nut torque values are listed in several places:
1776688884212.webp
 
Malleus said:
This really needs to be in the FAQ; I have not found a published torque specification for the joint between the transmission and transfer case, in any 80 service manual. It is in the LX450 manual, however:
View attachment 4125643
The driveshaft nut torque values are listed in several places:
View attachment 4125638
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Anybody have any idea why my shift linkage isn’t lining up? I’ve got the transfer case fully seated and most of the bolts in place. The transfer case looks like it says far forward as it it’s gonna go and the shift linkage is too long doesn’t line up on the bolt.
 
HHR137 said:
Anybody have any idea why my shift linkage isn’t lining up? I’ve got the transfer case fully seated and most of the bolts in place. The transfer case looks like it says far forward as it it’s gonna go and the shift linkage is too long doesn’t line up on the bolt.
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Here’s a photo.

IMG_6860.webp
 
HHR137 said:
Never mind, I just realized I’m retarded. I have my wife put it in low while I was underneath the car to line a pin up.
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Well I got it all back together. I believe I did it all correctly. I turned the car on and all the lights work, center diff engaged and shifts fine. I’ll take it for a drive later tonight.

However I noticed it now has a rough idle. Making having the battery disconnected for like 5 days reset the ECU? I recently changed the thermostat because this happened before. After changing thermostat it went away. Could anything I’ve done cause this 😂
 
It's just lonely. It'll be fine once you drive it.
 
Malleus said:
This really needs to be in the FAQ; I have not found a published torque specification for the joint between the transmission and transfer case, in any 80 service manual. It is in the LX450 manual, however:
View attachment 4125643
The driveshaft nut torque values are listed in several places:
View attachment 4125638
Click to expand...
This information is very helpful for me as I'm about to disassemble the transfer case. Thank you!
 
Malleus said:
It's just lonely. It'll be fine once you drive it.
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Last update, I believe it was probably just the ECU needed to relearn. I took it for about a 25-30 minute drive and the problem went away.

Thanks to everyone who helped me out. I have little to no mechanical experience and you guys helped a ton. Shoutout to whoever started this thread. You are the man! Hopefully someone else will find this helpful.
 
If you don’t have a lift, I used the HB small transmission lift, a 3ton low profile HB Daytona lift, and a power built jack stand/bottle jack combo. I think those three items suited me really well. I would add to that in any future attempt a rachet strap to keep the tcase secure on the HB transmission jack.
 
Adsing said:
If you don’t have a lift, I used the HB small transmission lift, a 3ton low profile HB Daytona lift, and a power built jack stand/bottle jack combo. I think those three items suited me really well. I would add to that in any future attempt a rachet strap to keep the tcase secure on the HB transmission jack.
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Great, have everything except for the transmission jack. Will pick that up.
 
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