Replacing a Transfer Case
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Replacing a Transfer Case
I have a 1992 with a 302. I posted awhile ago about my four wheel drive not working, and found out the transfer case is bad. Im gonna go to the junk yard and get a new one, but i was curious how hard it is to replace the transfer case and if there's any tricks or secrets to it. Should i take it to a shop to do it or is something that i can do myself. im not a master mechanic but cars do interest me and i know a little bit.
Postmaster
Joined: Nov 2011
Posts: 3,533
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From: SW Florida
It's real easy to do, shouldn't take more than an couple hours if even that. Grab a socket set, a couple combo wrenches, and some beers.
Drain the t-case and pull the driveshafts. Rear has to unbolt from the axle pinion, then slide it out of the t-case. The front one can just unbolt at the t-case u-joint.
Disconnect the wires (and linkage if manual shift) and take the bolts out holding the t-case to the transmission.
Might have to give it a little persuasion but it should come straight back and off. Clean the gasket surface of the transmission, put your new gasket up there, and reverse everything you just did to get the new one bolted up.
A friend might be helpful, but I did mine alone. Just plopped the case right on top of me and slid under the truck with it so I could lift it straight up and see what I was doing easier.
Drain the t-case and pull the driveshafts. Rear has to unbolt from the axle pinion, then slide it out of the t-case. The front one can just unbolt at the t-case u-joint.
Disconnect the wires (and linkage if manual shift) and take the bolts out holding the t-case to the transmission.
Might have to give it a little persuasion but it should come straight back and off. Clean the gasket surface of the transmission, put your new gasket up there, and reverse everything you just did to get the new one bolted up.
A friend might be helpful, but I did mine alone. Just plopped the case right on top of me and slid under the truck with it so I could lift it straight up and see what I was doing easier.
Senior User
Joined: Dec 2012
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From: Coastal Washington State
It's not bad. I just did mine. Dixie 460covered it pretty well. Once the bolts holding the transfer case to the tranny are loose I just rocked up n down a little to get it free. There's a dowel pin that keeps it in the right spot for getting the bolts in. Once it's loose it just slides back. I'd guess it weighs about 50 pounds. For reinstall it's helpful to have one of those cheap fluid pumps from the auto parts store to pump the new ATF into it.
Logistics Pro
Joined: Mar 2005
Posts: 4,698
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From: Mexico, Missouri
Just noting, should chalk mark, scribe line where the driveshaft meets the axle pinion, so to keep the correct factory balance and factory placement when re-installing. May or may not make a difference. Just a thought..
New User
Joined: Sep 2012
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Just the gasket between the transfer case and the tranny. This would be the optimal time to replace u-joints in the drive lines or a carrier bearing if they are wearing out.
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Postmaster
Joined: Nov 2011
Posts: 3,533
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From: SW Florida
I would open the case up and do the oil pump retainer fix, or at least inspect the condition of the existing setup, since this is probably why your old t-case failed... although that's just a guess.
With higher mileage the oil pump retainer wears out it's retainer groove in the case, finally breaks free, then spins round and breaks one of the shift forks... I think the range fork is the one that breaks. Then other stuff breaks from lack of lube.
There's a few ways to do the fix, what I did is just take the retainer bracket and welded a bolt onto it so that it has a wider contact patch on the case.
With higher mileage the oil pump retainer wears out it's retainer groove in the case, finally breaks free, then spins round and breaks one of the shift forks... I think the range fork is the one that breaks. Then other stuff breaks from lack of lube.
There's a few ways to do the fix, what I did is just take the retainer bracket and welded a bolt onto it so that it has a wider contact patch on the case.
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