Well i got it all done tonight, it was actually really easy. If i had been able to use my impact gun i would have been able to do it in half of the time, but right as i was starting my tow behind compressor/generator it decided to blow a fuse on one leg of the generator, then did it two more times so i just left it behind. I have a 60 gallon at home but i dont have one at the warehouse i was using.
Anyway it took me about 5 hours entirely by myself including the time to run out to buy a 15/16th wrench and bolts. When i got the old transfercase off i realized there were studs in it. I'm not sure how you guys remove them but i removed the 3 body mount bushings, and just maneuvered it around very easily from underneath with my legs. The chainfall hoist i had had a long enough chain to reach the floor so i was able to raise and lower by myself and move it effortlessly to both remove it and install it. I used a chain through bolts at about 10 and 11 and it balanced pretty much perfectly. I ended up just using some 5/8" brad 8 bolts, washers, and lock washers in place of the studs. A couple of the studs came out removing the brackets and i noticed they are only threaded in about .5". I have 2" bolts in there now which is why i had to use 2 washers. I also made a thread chaser to clean out the threads since they had sat.
If i had an impact to use i could have done it in under 3 hours im sure. The part that took me the longest was unbolting all of the driveshafts being they were all split nut jam nuts, and impacts and extension would have done it in seconds over a ratchet and wrench. Removing the brackets and changing over everything took a little while too. In all it wasnt too bad. I drove it around the parking lot, tested everything out it works great. The old one didnt have any shaft play or binding or anything, it probably would have lasted another 20k plus. But atleast now there is a brand new transfercase in it
I did find a couple cool things when i took the seat out, a CO2 looking canister marked Nitrogen which clips into a place in the cab above when im assuming a fire extinguisher should be and i also found what looks like a blank inside of a hole in the frame. I am not exactly sure what it is though