I was just wondering if anyone has replaced their transfer case or has a link to instructions on replacing it? The one in my Dad's 2000 Expy is toast. It doesn't look like it would be too bad, the torsion bars look like the hardest part.

 

Anyone???

 

It's just nuts and bolts. The bars will be the easiest part. Just loosen up the adjustment bolts and take them out. You'll want to support the frt end first but you should have it up on jack stands by then. The rest, like I said, is just nuts and bolts.

 

so its possible to replace them your self with out taking the engine out my transfer case jsut twent and i spent 1200$$ on a new 1. that feels like ****

 

YOU DO NOT PULL THE ENGINE FOR THIS JOB! With average mechanical skills I think that this is a Saturday job. Get some help from a friend, believe me, you can do it yourself.

 

Sounds good, thanks TROPHYMAN.

 

Happy to help

 

I'm looking at doing this same job on a '97. The torsion bars look to be the hardest part of the job for me. I've already been under the truck, unbolted the left torsion bar and no go - it wouldn't budge. Maybe I'm doing something wrong.
Please let me know how this worked out for you and any trouble spots I should be aware of. Thanks.

 

So you loosened the adjustment bolts, right? Now just use a hammer to free the bar from it's position. Use some WD-40 to assist.

 

Thanks TROPHYMAN
I did... however the adjuster cam on the end of the torsion bar didn't want to come off and the front end of the torsion bar didn't budge in the lower control arm.
So, I sprayed everything with PB Blaster and put it all back together. I'll give it another go this weekend.