Hi guys..Long time member first time posting. First I just wanna say that this site is the best. Never needed to post before to day because the answer to any question I had is floating around here somewhere.

So I need to replace the transfer case motor but the two wires that lead to the transmission tail shaft have me stumped. I'm sure they are for some type of speed sensor but how do I disconnect them from the motor itself. One is a ground and the other goes into the tail shaft. The truck is an 07 model.

Thanks,

Stephen

 

not 100% sure but it may actually be a vaccuum sensor

 

To clear things up a bit, these two wires go from the transfer case motor to the transmission tailshaft. They are not part of the plug-in harness. One these two wires is grounded on a tailshaft boltn the other goes into the the tail shaft.

 

Basically what I'm asking is how do I get the motor out with these two wire connected to tailshaft. They have no disconnect plug and the pics of the motor doesn't show these two wires.

 

Above(Specialty tools)






Disassembly








Transfer Case Exploded View - Manual Shift









Transfer Case Exploded View - Electric Shift

NOTE: On the manual shift transfer case, place the transfer case in the neutral position for disassembly.

1. Remove the transfer case

2.Remove the 4WD indicator switch, if equipped.



3.Using the special tool, secure the transfer case.



4. Using a suitable tool, remove the oil seal.




5. Remove the coil wire from the electric shift motor electrical connector, if equipped.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the wire connector spacer. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the coil wire and pin.</TD></TR></TBODY></TABLE>

• Use an electrical connector pin extractor tool.

6.Remove the Output Shaft Speed Sensor (OSS) , if equipped.



7. Remove the transfer case shift motor, if equipped.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the bolts. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the transfer case shift motor.</TD></TR></TBODY></TABLE>



8. Remove the extension housing.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the six extension housing bolts. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the extension housing.

</TD></TR></TBODY></TABLE>



9. Remove the speed sensor tone wheel, if equipped.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the tone wheel spacer clip. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Pull off the speed sensor tone wheel and discard.
</TD></TR></TBODY></TABLE>




10. Remove the rear output shaft snap ring. IA up on the output shaft while removing the snap ring



11. NOTE: The bolts are self-tapping, and it is normal to find metal shavings while removing the cover. Remove the bolts.




12. NOTE: Use pry bosses to separate the cover from the case. Separate the transfer case covers.



13. Remove the coil.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the three coil-to-cover nuts. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the coil.
</TD></TR></TBODY></TABLE>




14. Using the special tools, remove the rear output shaft bearing



15. Using the special tools, remove the front output shaft bearing.



16. Remove the shift collar hub soap ring



17. Remove the coil housing.



18. Remove the shift fork.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the lockup hub. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the shift fork and spring.</TD></TR></TBODY></TABLE>



19. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with the following. Disassemble the lockup hub assembly.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the lockup hub snap ring. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Separate the lockup collar. </TD></TR><TR><TD vAlign=top>3</TD><TD vAlign=top>Separate the two lockup springs. </TD></TR><TR><TD vAlign=top>4</TD><TD vAlign=top>Separate the lockup hub. </TD></TR><TR><TD vAlign=top>5</TD><TD vAlign=top>Remove the armature.
</TD></TR></TBODY></TABLE>




20. Remove the spacer.



21. Remove the drive chain and sprockets as an assembly.



22. Remove the magnet from its slot in the case.



23. NOTE: The pump assembly is not repairable. Remove the oil pump and the output shaft as an assembly.

24. Remove the shift rail.



25. Remove the shift fork and the reduction hub.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the shift fork.</TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the reduction hub.</TD></TR></TBODY></TABLE>

26. WARNING: Do not disassemble shift cam assembly. Remove the electric shift cam assembly, if equipped.



27. Using the special tool, remove the input seal.



28. CAUTION: Do not let the front planet carrier fall while removing the snap ring. Remove the front planet carrier.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the front planet carrier snap ring.</TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the front planet carrier.
</TD></TR></TBODY></TABLE>


29. If necessary, using the special tools, remove the bushing from the front planet.


30. Using a drift and a hammer, remove the needle bearing, if necessary.



31. Remove the ring gear.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the ring gear snap ring. </TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the ring gear.</TD></TR></TBODY></TABLE>



32. Remove the front planet carrier bearing snap ring. Then, using the special tools, remove the front planet carrier bearing.



33. CAUTION: Do not let the front output shaft fail while removing the snap ring. Remove the front output shaft.
<TABLE border=0 cellSpacing=10 cellPadding=1><TBODY><TR><TD vAlign=top>1
</TD><TD vAlign=top>Remove the front output shaft snap ring</TD></TR><TR><TD vAlign=top>2</TD><TD vAlign=top>Remove the front output shift.</TD></TR></TBODY></TABLE>


34. Using the special tools, remove the front output shaft bearing


35. Using the special tools, remove the front yoke to flange seal.



36. NOTE: Access the shift. lever set screw through the 4WD indicator switch hole, if equipped. Loosen the shift lever set screw.



37. Remove the shift lever (from outside of case), shift cam detent spring and detent roller, if equipped.



38. Using the special tools, remove the shift lever seal, if equipped.



39. Using a suitable pry tool, remove the electric shift motor seal, if equipped.



40. Remove the dust shield, if necessary.


I know theres a bit more than needed but I figured it would come in handy

all info above is from www.alldatadiy.com

 

Thanks.....there is a lot of info in the above post but it really doesn't help me with those two wires.

Stephen

 

i don't understand how the two wires affect what you trying to do???

 

They are connected to the transfer case motor and the tailshaft they are not part of the plug in harness on the truck. There are no disconnect plugs. Unless I those wires, I cant get the transfer case motor out.

 

Another clarification......one wire coming off the motor is grounded on a tailshaft bolt. The other wire goes into the the tailshaft itself. After unplugging the harness and unbolting the motor, these wires are the only thing from keeping me from getting this motor off the truck. The wire that is grounded to the bolt is easy enough but the wire going into the tailshaft has no way (that I can see) to disconnect. Any help with this would be greatly appreciated.

Stephen