My transfer case boiled all of the ATF out of it and needs to be rebuilt or replaced. How difficult is it for a reasonably coherent shade-tree mechanic to pull the transfer case and replace it with a rebuilt unit? Since the unit became hot enough to boil the ATF should I rebuild the original or replace it with an already rebuilt unit? Any help or advice you could provide would be greatly appreciated. Thanks, Bill.

 

What do you mean by boiling atf?

Yes, the transfer case is a simple piece that can be rebuilt with tools either in possession or easily obtainable with a trip to the part store. It's the easiest piece in the drivetrain. If ya get overwhelmed, can always source a jy case.

 

I'm not sure about the rebuilding part. When mine in my 89 went, it spun the oil pump and damaged the case. I ended up needing to purchase a rebuilt. The job of swapping it out isn't too bad. I chose to replace all my u joints in the font and fear driveline a while I had it apart. I'd say probably a couple hours to disassemble and an hour and a half to reassemble. It just depends on how stuck bolts are and how many trips you have to make to the toolbox

 

Rebuilding your transfer case is easy! The only thing that will **** you off is if you don't have GOOD snap ring pliers handy. Not the cheap junky ones with the little interchangeable tips, go to Sears and get the reversible ones with the fixed tips. Those are good enough.

Oh and when you want to pull the pilot bearing in the cover, if you don't have a blind hole bearing puller (or if you do and it won't budge the bearing) then take a hammer and chisel and whack the bearing til it's in enough pieces that you can pry it out. Careful not to damage the case! It's only aluminum.

Here's a writeup on how to do it:

Rebuild your own transfer case. BW1356 - FSB Forums

Pay attention to the oil pump plungers, and also be sure and do the oil pump retainer fix while you're in there. I welded a bolt to mine.

EDIT: I mean pay attention to which way the plungers come out. If I remember right they can go in either way, but when I rebuilt mine I didn't realize that til reassembly. I could not find any info on which way they went so I put on in one way and the other in the opposite way. It ain't blown up yet...

 

Thank you everybody for the response and excellent advice. I am going to tackle it myself.

As for boiling my ATF ... When I got off the interstate and backed the truck into the garage something smelled real strange. I looked under the truck the next day, there was a dark brown substance on the floor. The tail shaft of the transfercase was also covered in the dark brown shiny substance. I am assuming that the ATF got so hot it boiled out.

Thank you for all of the assistance. Bill