So my 03 of course has no CDL. I know there are two options to either replace whole t case or just the innards. I plan on putting in a used t case. To be honest I haven't even looked at the rave manual. I have crawled under this truck many times and it seems VERY daunting removing a t case. I dont like/am not familiar with working under the truck as far as transmission and t case. I'm sure I have the ability, I have done head gaskets and such but as I have recently learned doing damn drive shaft rebuild, just because I CAN doesn't mean I should/want to. May actually let a shop do it, all I ever let shops do is A/C and alignments, but maybe it would be worth my time,

Anybody have a basic description of how it's removed so I get an idea?

 

re: as I have recently learned doing damn drive shaft rebuild

Your instincts tell you the path - the choice is just which shop. Consider the money you save on all the other DIY projects and the cost of ownership still remains modest.

 

R&R of a transfer case isn't that bad.
Three things that help a lot:
- transmission jack
- LT230 adaptor to transmission jack (specs in the shop manual, I made mine)
- long bolts cut off to use as guide pins.
You can do it without all three, but they make it a lot easier.
Read the manual for how to do it, that's about as good as any description.

 

And go read the Rave, not sure why you didn't do this to start with.

 

R&R on a transfer case is really not a big deal. I'll be removing one from an '01 DII tomorrow. I have several LT230's from DII's with the nipple. I can get you one without the brake assembly shipped out pretty cheap. Then, once you get it I can walk you through removal and reinstall step by step if you need it.
Cheers,
Paul

 

Where are you located? I have a t-case out of my 01 with 108k miles on it ready to go. I swapped mine as I thought it made to much noise, turns out it is normal. I'm in central Indiana.

Swap was not bad, but it is involved. You will need to drop the exhaust, and crossmember to get it out, as well as removing the console to unplug and disconnect everything on top of the case. As mentioned, you will need a trans jack, as the case is quite heavy, and making a few guide studs is a very good idea as well.

 

Yeah OP i feel you on that. I want to convert my 03 to a 2004 eventually. Roof rails, emblem, CDL and all. Once I get enough cash I'm going to give Paul Grant a call. He's probably got the cheapest prices I've seen. Plus you know you are getting a good working part. The real pain is going to be finding a used 04 air shifter at a good price. I've also considered regearing to get more power back from my tire upgrade.

 

Becaus I'm working 12 hours a day 7 days a week, no time to search rave.
Just wanted a quick breakdown..

I'm sure I can do it minus the transmission jack and adapter. Is there any reason a floor jack, the kind with the wide support about 4" round woulnt work?

 

The biggest problem you will have with a standard jack is the part you are going to hold the transfer case up with is angled. You can't jack where it comes out of the tranny because all the weight is where the front output shaft is.

 

Ah! See this helps...

I'll check into cost at a shop but who knows