Well, this is a cry for help. I once thought I had a handle but am frustrated. I am trying to get the T-case and Tranny out of my truck. Lack of knowledge and 30 years of rust are getting the better of me. I have pulled the rear drive shaft.I have taken the tunnel out of the cab. I have unbolted the T-case from the center section. Heres my major issue: I cant seem to get at things. The front drive shaft is held in by 4 bolts. How does this remove? If I could get that out I would have all the room in the world. Whats the best way I should be approching this? Should the crossmember come out? I dont think I will get the T-case out because of some TARD that ran the exhaust right in the way. Ive spent 2 days and all thats been accomplished really is draining the fluids. I just dont know how to approach this.It just cant be that difficult. Please help.

Thanks

 

Sorry--351M, NP435 4 speed, NP205 T-case I think. 1977 F250 Highboy.

 

You got one of two options, to installing a flywheel.
One, remove the transmission and transfer case.
Two, remove engine.

The advantage of option two, is you can replace engine seals, gaskets and other engine parts needing replacing.

Does your truck have the driveshaft between the transfer case and transmission?

 

Yes it does. Atleast Im sure it does. There is about a foot space between the Tranny and Transfer case. Option 2 is out of the question because I barely have the resource to make option 1 happen. I dont have a garage and time is running out on good weather. My main question is: How does that shaft from the front driveshaft come out of the Tcase? If I can get that out of the way I would have a heck of an easier time with this.

 

Okay option one, is what we will discuss.

It will help if you can take the truck to car wash and wash down the frame, under the cab and under the truck, transmission, driveshaft and clean as possible. What you want to do is remove all the mud and sand embedded in those areas.

This are few parts that must be removed and always consider safety. If this is your first time, it might take two days, which includes running for parts and take 10 minute breaks here and then. If you have any questions, post here. Clean with wire brush any threads if possible and spray down with rust penetrator: the bolts, U-bolts, and nuts hours before removal.

I have a 1975 F250 Hi Boy with the same driveshaft between the transfer case and transmission and have replaced numerous clutches.

 

Use some type of storage containers (cans or cut bottles to make containers) or use zip loc bags to keep each items removed in their separate container. Such as when you remove the u-bolts, those will go in their separate container. When you remove the front crossmember bolts, those will be placed in their separate container, do this for each phase of removal of nuts and bolts.

Disconnect negative battery cable from battery.

Chuck block rear tires to keep truck from moving.

With a 1/2" wrench remove the u-bolts, that hold the drive shaft (intermediate and front). Sometimes it easier to remove those nuts if you wire brush the threads and spray with some type of rust penetrater. If you lock both front wheel locking hubs it will help to hold the front drive shaft from spinning while you break loose all the u-bolts holding the drive shaft. Keep one locking hub locked and the other unlocked, turn front drive shaft where you can have access with wrench to the u-bolts holding the drive shaft, then lock the unlocked hub. This will help to hold steady the drive shaft while you loosen the nut on u-bolt.

Loosen the exhaust from exhaust manifold and remove exhaust pipe from exhaust hangers, This will allow the transmission and transmission bell housing to be removed later.

Remove starter motor from transmission.

Remove bolts and tranmission cover.

Remove the rod from transfer case that attaches to the 4 wheel drive shifter. Loosen the and remove with big crescent wrench the big bolt holding the shifter for the 4 wheel drive.

Remove the clutch linkages and clutch equalizer bar.

Remove the with 3/8" wrench or socket the speed-o-meter cable, Use a sandwich bag or some type of plastic bag with sandwich or garbage ties on speedo, this will keep dirt out.

Loosen and remove the front crossmember that between the engine and transmission. This crossmember does not support the transmission. Mark this crossmember with the word front, it will help on the re-insallation.

Loosen the nut (9/16") from remove long bolt on transmission mount. Remove the nuts and bolts holding the tranmission crossmember. Place a 2 long boards under jack wheels, the jack will need to roll back, when the transmission is ready to be removed. Center jack on transmission, and remove nuts and bolts from transmission crossmember. Remove transmission crossmember.

Remove the six bolts holding the transmission.

Have an assistant help you lower the transmission. Think safety first.

 

So I am to remove the Tranny and T-case as 1 big friggin unit? That seems easier I suppose. I dont remember seeing a front crossmember. Just the one that runs under that housing that goes from the Tranny to the T-case.I will have to take a look tonight when I get home.

Thanks

 

The transmission will be removed only, the transfer case will remain on truck.

It should have a front crossmember, it mounts right between the bell housing and the transmission.

Take the transmission out, as one unit, bell housing and transmission.

Forgot to mention, Drain gear oil out of transmission, prior to dissassembly. If the transmission tips to one side, it dosen't make a oily mess.

The front cross member and transmission crossmember, mark both with front, it will make installing them much easier if you have some reference mark on the front portion of these crossmembers. If you plan on clean and painting them, make sure you know which is the front part, it will save you time and eliminate any confussion.

It's probably a good time to replace the clutch disk, pressure plate, throw out bearing, pilot bearing, if they show wear marks.

 

wish i would have known that to begin with. I still cant recall a crossmember inbetween the bell housing and tranny. The big crossmember between the frame rails that runs under the T-case is the one I have been struggling with. How does the Tranny come out without removing the rest? there is a shaft that runs out of the tranny right? Ill trust ya but it just seems like there wont be enough room.

 

Let me know if the transfer case is attached to transmission?

The removal will be a bit different.

 

The Tranny is connected to the Transfer case by about a foot long sleeve. i finally got the crossmember out after alot of heat and swearing

 

What parts have you taken off?

 

Havent gotten anything out yet. Now that I have that crossmember out I can actually get at things. Sure is alot easier with that out of the way. I think I am one nut away from the T-case and sleeve coming out. Out of the 4 nuts that are holding the tranny to that sleev I have 3 of then off and the other is froze on so when I get home today I will be firing up the torch again and taken that off. Then the whole thing should drop. Then as far as getting the tranny out shouldnt be a problem but I have never pulled a manual so I am in the dark about the clutch. I just want to make sure everything goes back together correctly.

Ps I will be replacing ALL the hardware so next time if there is one this will be way easier. Rust sucks

Tommy

 

Okay the truck has the transmission adapter to T-case.

Remove transmission boot from inside of cab.
Remove transmission shifter.
Remove the transmission cover from inside of cab.

Should loosen the bolts at T-case to transmission adapter.
Make sure to drain oil from the T-case.
Speed-o-meter should attach to T-case.

Might need to loosen exhaust from exhaust manifolds to gain extra clearance when removing transmission and transmission adapter.

One tranmission is removed, loosen the six bolts with lock washers holding clutch pressure plate. If lock washers are worn replace them with grade 8 locking washer.

The flywheel is next.

Use the pilot bearign removal, you can rent one (money deposit) at Autozone, when you return the tool, they will give you the money back (money deposit), there fore you can use the tool for free.

There is two types of pilot bearings, bushing or bearing style.

Grab a couple cans of brake cleaner, it will help in keeping oil and grease off clutch, flywheel, clutch disk, and will help to keep things clean.

Make sure to clean the output shaft on front of transmission, and regrease.

 

I got the T-case out. That was a huge pain in the rear. Anyway after i pulled out the T-case (let it drop somewhat after I lost control of it) The were some pieces that looked like a plastic gear that crumbled inside the T-case. There isnt any plastic gears in there are there? It almost looks like hardened grease or something. There wasnt enough of it to be a full gear or anything.Its a NP205 and I just want to make sure that nothing inside is ruined otherwise I will have to get it rebuilt. I didnt get the Tranny out yet but that sure looks like alot easier project. I had to cut the exhaust due to a poor routing job done by the previous owner which is OK cause I wouldnt mind replacing anyway. I will have to get the Tranny out tomorrow.

I do thank you for the help. Its been very helpful. Sorry if I wasnt clear on the whole adapter thing. I guess Im not positive on what a divrced T-case means. I thought what I have is a divorced T-case.

Thanks
Tommy