Might be easier to just pull the top housing and work with it on the bench.

 

That's a good idea I will try it

 

I was thinking of wedging a small socket with some wood behind it, and also possibly using some heat to expand the bracket hole. Just be careful to not light the whole thing up in flames.

 

Vice grips...put one jaw on the side of the pin you want to push from and the other jaw on the top of the linkage (as close to the pin as possible) and clamp down. Unclamp, tighten screw a tad, reclamp...repeat.

 

Co-signed. It's all of 4 bolts.

Just make sure the area is cleaned proper before you remove that housing. You don't want any stray dirt to fall into your transfer case.

 

No luck again today, Man im so fed up with this thing. Tried the vice grips on one side then squeezing and nothing just mushroomed it out a little. I did get it to spin a tiny bit and then it froze up again. I'm stumped

 

Does anyone know if I can use an air hammer on the t case lever to try and get this pin out? Or am I taking to much of a risk in breaking the lever?

 

Again, go to a D1 shifter, save all that hassle and improve your 4 wheel performance.

 

I don't see how he can use a d1 shifter with that pin stuck in the transfer case lever. He can't connect any type of shifter right now.

An air hammer is a bad idea.

I feel like clamping the **** out of it with vice grips should work.

I think the next move (after you decide vice grips are not working) is drilling it out. You can use a dremel with a drill bit in it to get in there a bit easier. It also might help to cut some of the pin off with a dremel, then try to work the rest out with a drill to loosen it and a hammer and punch to get it out. But cutting it off might be a bad idea. I'm not able to really read the situation from here.

Somebody smarter than me - is it possible just to pull the lever he's messing with out of the transfer case? Mine seemed to float when I pulled the long bolts that secure its housing to the t-case, but I didn't know if it was safe to pull it out.

 

The lever is attached to a rod that is captive in the linkage housing. Pull the 6 bolts and the housing and be done with it. Or better yet, replace the housing with a D1 housing and shift linkage like I did.