Transfer Case Removal Question
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Transfer Case Removal Question
'99 Expy, 5.8L, AWD.
I'm swapping out my transfer case. I can't find my Service Manual CD.
Do I have to remove the transmission cross-member and mount to get at the bolts that hold the xfer case to the trans? It seems that if I did, it would give me good access. If it's not necessary, is there a tip or trick to getting the bolts out?
The Old Lady is all over me to get this done
so any help is greatly appreciated!!
TIA!
I'm swapping out my transfer case. I can't find my Service Manual CD.
Do I have to remove the transmission cross-member and mount to get at the bolts that hold the xfer case to the trans? It seems that if I did, it would give me good access. If it's not necessary, is there a tip or trick to getting the bolts out?
The Old Lady is all over me to get this done
so any help is greatly appreciated!!TIA!
Fleet Owner
Joined: Apr 2008
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From: 0,0,1
Definitely support it, otherwise you can tear the rubber in the two motor mounts, or pull on wires and vacuum lines until they break as the tranny/engine assembly sags down. Try not to support it by the pan. But if you have to, place a piece of 2x4 (or similar) between the pan and the jackstand to help distribute the weight across the entire pan.
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AP....thanks for your guidance through this project. A buddy stopped by right when I was ready to remove the old xfer case and he helped put the "new to me" one in. After that it was just a matter of putting everything back together.
Test drove it and everything works as it should. No "bound up" front wheels in AWD. I'm thinking about doing the "brown wire mod" as well.
Thanks again!!
Test drove it and everything works as it should. No "bound up" front wheels in AWD. I'm thinking about doing the "brown wire mod" as well.
Thanks again!!
Fleet Owner
Joined: Apr 2008
Posts: 24,316
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I hate to say it, especially after the time, blood, sweat, and effort but the original issue is back.
After doing the xfer case swap I test drove it (through about 4" of fresh powder) with no issues noted. (last night)
Today I notice "clunks" in the front driveline while in AWD, usually after a turn. Going in a straight line is pretty normal....after the clunk when you straighten out.
I pulled fuse 104 under the hood and the binding got a bit better but is still there as noted above, during and after a turn.
Having swapped the xfer case and pulling the fuse, wouldn't the only thing left be the front hubs locked engaged?
Any help is greatly appreciated.....this was so disappointing!!!
After doing the xfer case swap I test drove it (through about 4" of fresh powder) with no issues noted. (last night)
Today I notice "clunks" in the front driveline while in AWD, usually after a turn. Going in a straight line is pretty normal....after the clunk when you straighten out.
I pulled fuse 104 under the hood and the binding got a bit better but is still there as noted above, during and after a turn.
Having swapped the xfer case and pulling the fuse, wouldn't the only thing left be the front hubs locked engaged?
Any help is greatly appreciated.....this was so disappointing!!!
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Logistics Pro
Joined: Jan 2001
Posts: 3,740
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From: Central NYS
Does the 1999 Expy have a 2WD position on the selector switch?
Logistics Pro
Joined: Jan 2001
Posts: 3,740
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From: Central NYS
Okie-dokie. (I have trouble remembering when the 2H went away.)
So, TX76F250, any warning lights on the intrument panel?
And did you check fuses 6, 8, 15, 20, and 23 in the CBJ (that would be the Central Jucntion Box under the dash)?
So, TX76F250, any warning lights on the intrument panel?
And did you check fuses 6, 8, 15, 20, and 23 in the CBJ (that would be the Central Jucntion Box under the dash)?
Logistics Pro
Joined: Jan 2001
Posts: 3,740
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From: Central NYS
Must be the front hubs, axle halves, and front diff are not the issue.
So I'm thinking the issue is within the transfer case or transfer case shift motor. I'd put the front driveshaft back in and drive it in both A4WD and 4H to see if there is any difference between A4WD and 4H.
Also, are there any codes in the PCM? For example, both the PCM and the GEM receive the TPS signal. The GEM uses the TPS signal to anticipate rear wheel slippage when in A4WD. If the TPS signal has any drop out the GEM might be activating the TOD function when it shouldn't.
All four tires are the same size?
So I'm thinking the issue is within the transfer case or transfer case shift motor. I'd put the front driveshaft back in and drive it in both A4WD and 4H to see if there is any difference between A4WD and 4H.
Also, are there any codes in the PCM? For example, both the PCM and the GEM receive the TPS signal. The GEM uses the TPS signal to anticipate rear wheel slippage when in A4WD. If the TPS signal has any drop out the GEM might be activating the TOD function when it shouldn't.
All four tires are the same size?
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