Removing The Transfer Case (TC)

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HHR137 said:
Day 3: I am doing this in very small parts just when I have time. Today I was able to remove the front driveshaft from the TC. Again took a lot of wiggling but eventually came off. I then removed bolt 4. I am having terrible luck with every bolt/nut so far. They are incredibly seized. I was able to break it free using a 5 in extension and a breaker bar. I then removed the speedometer cable and the electronic diff lock connection. The speedometer cable connection blocks the access of bolt # 5 so I had to remove the entire cable. This was a pain and I accidentally broke the plastic bracket that connects it to the TC. Not a huge deal as I am sure I can secure it some other way. Also, in case this helps anyone. Be careful not to put too much force on the transmission pain when removing bolt #4. It can be easy to use as leverage.

Tomorrow I’ll be doing bolt 5 and the remaining bolt with the exception of 6 should go very fast. I will probably drop the TC Saturday. I obtained a second floor jack and will hopefully have a buddy help me. I don’t want to spend the money on a transmission jack so I am hoping we can just guide it down.

I attached a picture. Red is how the speedometer cable connection blocks bolt 5. Green is the diff lock motor. I haven’t seen where the cotter pin connection is. It was reference earlier in this thread. If anyone can tell me how to find it I would appreciate it.

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Day 2: continued

Had some more time today. I removed that hair pin. See the attached pictures. Didn’t have long enough needle nose pliers so I used a very small flat head screw driver and it popped right out. I also disconnected a few other electrical connections on the back of the TC. These were very easy. Tomorrow I will tackle bolt # 5 and all the hard stuff should be behind me. Bolt 5 seems like it will be a pain. Not sure if i have the right tools but we’ll find out tomorrow.

Pro tip: when you remove the pin, keep in mind two washers will fall. Fortunately I found them both.

IMG_6842.webp


IMG_6843.webp
 
Buy a new one; it's a spring and springs weaken over time.
 
HHR137 said:
Day 2: continued

Had some more time today. I removed that hair pin. See the attached pictures. Didn’t have long enough needle nose pliers so I used a very small flat head screw driver and it popped right out. I also disconnected a few other electrical connections on the back of the TC. These were very easy. Tomorrow I will tackle bolt # 5 and all the hard stuff should be behind me. Bolt 5 seems like it will be a pain. Not sure if i have the right tools but we’ll find out tomorrow.

Pro tip: when you remove the pin, keep in mind two washers will fall. Fortunately I found them both.

View attachment 4123565

View attachment 4123566
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Day 3: I’ve removed bolt 5 and 1. Bolts 2-3 are finger tight. Hoping someone can help me. Do I need to put wood blocks under the transmission pan or can I put a jack under where the TC and transmission meet. Then remove the transmission cross member and place another jack under the transmission mount. Then lower the TC.
 
HHR137 said:
Day 3: I’ve removed bolt 5 and 1. Bolts 2-3 are finger tight. Hoping someone can help me. Do I need to put wood blocks under the transmission pan or can I put a jack under where the TC and transmission meet. Then remove the transmission cross member and place another jack under the transmission mount. Then lower the TC.
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I used a piece of plywood on the trans pan (after removing the little metal guard) to distribute the weight and not concentrate it at the point of the jack. I had no choice but to place it there with my set up.
 
Adsing said:
I used a piece of plywood on the trans pan (after removing the little metal guard) to distribute the weight and not concentrate it at the point of the jack. I had no choice but to place it there with my set up.
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Anybody have any ideas? Everything is off and I believe all the electrical connections are disconnected. At least the ones I can see. I cannot get it separated from the transmission.
 
HHR137 said:
Anybody have any ideas? Everything is off and I believe all the electrical connections are disconnected. At least the ones I can see. I cannot get it separated from the transmission.
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Pictures would help. Are you still asking about supporting the transmission or have you moved to how to separate the trans & TC? Overall you need to support the weight of the transmission being careful as already said to distribute the weight as evenly as possible under the transmission pan so you do not damage it.

As far as getting the two separated it's been a few months since I did mine but I don't recall it being too difficult to get them separated. Sounds like you have done this already but make sure to still have some bolts loosely holding the TC to trans so once it starts moving it can't move too much. If it does not want to separate you might have a bad angle on your TC causing the trans output and TC input shafts to be binding and hanging on to each other.
 
Yeah, some specificity is helpful here. But, as far as separating, the t case and the Trans mate with the shaft. There are also alignment pins as well. These can make the fit up tight, and I used a 2x4 and mallet to gently convince them apart.
 
There are a few pry points you can use to help
Separate the two, once it’s starts coming apart, it’s usually pretty simple and easy from there.
 
Rdonahe said:
Pictures would help. Are you still asking about supporting the transmission or have you moved to how to separate the trans & TC? Overall you need to support the weight of the transmission being careful as already said to distribute the weight as evenly as possible under the transmission pan so you do not damage it.

As far as getting the two separated it's been a few months since I did mine but I don't recall it being too difficult to get them separated. Sounds like you have done this already but make sure to still have some bolts loosely holding the TC to trans so once it starts moving it can't move too much. If it does not want to separate you might have a bad angle on your TC causing the trans output and TC input shafts to be binding and hanging on to each other.
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I am trying to separate the TC from transmission. I have a jack under the spot where the support bracket goes. The other jack is under the TC. Trying to find the right angle is tricky lol. Idk if I am to low or high. Also I circled what looks like a gap. It’s separating very slowly
 
HHR137 said:
I am trying to separate the TC from transmission. I have a jack under the spot where the support bracket goes. The other jack is under the TC. Trying to find the right angle is tricky lol. Idk if I am to low or high. Also I circled what looks like a gap. It’s separating very slowly
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IMG_6850.webp
 
Red circles are the alignment pins. And then you can see the shaft from the trans. It’s a nice tight fit so as expected there will be some resistance for getting them apart. Be sure that the hand tightened bolts are only threaded in a few threads as you will prevent separation.

IMG_0357.webp
 
Adsing said:
Red circles are the alignment pins. And then you can see the shaft from the trans. It’s a nice tight fit so as expected there will be some resistance for getting them apart. Be sure that the hand tightened bolts are only threaded in a few threads as you will prevent separation.

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I’ve been at this for like 2 hours lol. Can’t get it off I’ve got a gap but it just won’t break free lol.
 
Make sure to go over the obvious things to see if something is encumbering it. I recall a few wire harnesses that need to get unbolted to make sure it’s truly free.
 
HHR137 said:
Does it have to be in a certain gear?
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Not that I’m aware. The shaft is captured and slides into the input for the Tcase. I feel like something up top is encumbering it from moving. Did you lower the transmission and all about 2in or so? I’m assuming so if you got the bolts off.
 
I would suggest taking your phone, getting some good light, and videoing the upper cavity. Might reveal if there is something binding.
 
Adsing said:
I would suggest taking your phone, getting some good light, and videoing the upper cavity. Might reveal if there is something binding.
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Yeah I’ll try tomorrow. I believe everything is disconnected. I had to lower it to get bolt 6.
 
Adsing said:
Red circles are the alignment pins. And then you can see the shaft from the trans. It’s a nice tight fit so as expected there will be some resistance for getting them apart. Be sure that the hand tightened bolts are only threaded in a few threads as you will prevent separation.

View attachment 4123903
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Are those pry spots between bolts 1-2 and 5-4?
 
HHR137 said:
Would it be worth lowering the transmission very low?
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I've had luck tilting the transmission/transfer case and then sliding the case off the transmission. You absolutely have to support both the transmission and transfer case well during removal; a good rolling jack or a very strong boy is essential.

Those alignment dowels are really long and the case has to come off straight; any misaligment and it'll bind. Be really careful using steel prybars; the mating surfaces are machined aluminum. Screw them up and you'll be sorry.

For what it's worth, I'd never try to mate a transmission and transfer case under the truck, unless I absolutely had to do it. It's too much trouble.
 
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