Morning All -

I'm just about ready to start my transfer case job. I've watched several videos and forum threads about what others have done. I'm going to try removing it solely from the bottom first, but if those top two bolts are proving to be to much of a bear, I'll remove the center console assembly and attack them from the top.

From those of you who have done it or helped a friend - should I just go straight for the console removal or ... ?

Secondly, in the service manual, they refer to the special tools to install the (3) seals on the transfer case. Are these required? I've read something about making sure you position them correctly, but nothing more than that really. Can I do this job w/out them? Thanks in advance.

- Jeremy

 

Well, transfer case is out. It's not as bad as I thought it was going to be. I took care of the top (2) 13 mm bolts with the torque adapter and 3/8 socket extensions. I watched a video on YouTube where the guy said it was almost impossible, but you have to have the torque adapter to make it all work. Not bad, just time consuming.

I had this gunk on the transmission output shaft and on the input splines of the transfer case. Anyone know what that is? Looks like dirt/dried up grease, but I'm not sure. I think for the seals, I'm just going to 3D print some flattened tubes to tap the seals in and measure the depths before removing the existing ones so that they are placed in the same place.

 

I don’t know what the crud is. But all of them have it.

Great idea with the 3D printer!

 

Thanks, so I'll clean it off, but do you know if I need to "grease" the splines or anything?

 

Does anyone know how to remove this "circlip". Do I just get at it with a flat head and/or o-ring removal tools?

 

Got the shaft out. I read on another forum where the guy used paper clips to keep the circlip "compressed" and then smacked it with a hammer. I tried this several times to no avail. So I put the paper clips in the circlip to compress it, then used a shop press to push it out. Worked like a charm.

There was mud behind the seal. Maybe how old the seal was with it also being submerged in quarry mud cause it to leak. Now to start putting her back together so I can be on the road again. Hope this helps someone else that is looking to do the job. Having the appropriate tools is half the battle.