Transfer Case removal/replacing

[stancanpara]

Ok, I've got to replace the transfer case in my Deuce... Had the usual grinding, noice, pops out of gear etc... When changing the oil, found rather large chunks of metal that appear to be casings from a bearing...

Thanks to my buddy Wade, I have a donor for it.

Question, who has done a transfer case replacement? I don't have a shop, but have borrowed a heavy duty transmission jack...

Are there any morsels of advise anyone can give me for this? I've read in threads from some that it's the worst pain in the @$$ and from others that it's a piece of cake...

Any and all suggestions are welcome. Thanks!

 

[BFR]

Clinto and I did mine and it was pretty straight forward. I would advise the use of a chain fall from above (will require the removal of the bench seat) suspended from either a cherrypicker in the passenger door or a beam accross the tops of the doors (windows down). Also, remove the spare to make it easier to slide the old one out & the new one in on a moving dolly.

 

[BFR]

Also, I would consider picking up all new hardware for the driveshaft between the trans and transfer. Maybe some locktite there as well.

 

[stancanpara]

Also, I would consider picking up all new hardware for the driveshaft between the trans and transfer. Maybe some locktite there as well.

Who would have that hardware readily available? I presume you mean the short shaft and u-joints.

Also, when you say chain fall, you mean lowering it down instead of using the transmission jack?

 

[stancanpara]

Also, are there any 'specialty' tools that would make the job any easier/efficient?

 

[91W350]

I think he means the bolts and lock nuts, especially new lock nuts. They are really bad about working loose on their own after the first or second time being run on. Glen

 

[73m819]

Who would have that hardware readily available? I presume you mean the short shaft and u-joints.

Also, when you say chain fall, you mean lowering it down instead of using the transmission jack?

HARDWARE means the NUTS and BOLTS, NO special tools

 

[stancanpara]

Great thanks for your input. New nuts and bolts is always a good idea (thanks for the reminder) specially for those hard to reach places!

Thought about taking the bed off... would this make the job any easier, or be more trouble than it's worth?

I'm getting started on this tonight... Burning too much daylight so probably won't be getting TOO much done until tomorrow...

Here are some picks of the donor....

 

[BFR]

Who would have that hardware readily available? I presume you mean the short shaft and u-joints.

Also, when you say chain fall, you mean lowering it down instead of using the transmission jack?

Just the nuts/ bolts. I would try a real hardware store ( not home depot).

Yes on lowering from above. A trans jack might work fine, but I really like how the chain fall worked. The transfer will want to rotate when unbolted from the frame. Not a big deal when suspended from above, but probably interesting if it is balanced on top of a jack 3' off the ground.

If you have the means to easily lift the bed off/ on it might be worth it just to make setting up the parking brake easier.

No special tools except what you use to raise/ lower the case.

 

[stancanpara]

Thanks BFR, I appreciate your input.

 

[fasttruck]

Bar across doors and chain fall is technique for removing transmission. Transfer cased rfequires a jack from below and a good floor or smooth work surface. P[roblem is to balance vee shaped t case on jack. People that did this all the time fabricated special braces to correctly support unit. Think about putting front wheels on blocks first to improve ground clearance to get old out and new in under truck. Remove spare as described before also.

 

[rebel_raider]

I agree with BFR. Take out the bench seat, both tunnel covers, and remove the spare. A cherry picker through the passenger door works very well. Shouldn't take more than an afternoon.

 

[ODdave]

I like the pto on that t-case

 

[73m819]

In my 819 (5t), i used come-a longs with small snatch blocks, took more time to get the xcase ready to drop and hooked back up then the dropping and reinstall, pulled the passenger seat and both floor panels, put a pipe though the right front and the rear windows,
The big thing is to THINK AHEAD, If your doing things by youself like I do it is even MORE important to do so and DON'T get in a HURRY

 

[Bill W]

I removed the seats and used a comealong hooked to a steel horse set inside the cab (1200lb rating ) that they sell at Homedepot for $25., other than time consuming very straight forward and simple

 

[stancanpara]

Great! Thanks everyone for your input. Great help!

 

[jesusgatos]

Am sure the hoist on the doors method works great, but I used a large transmission jack. Made it very easy to adjust the angles and get everything lined-up right (was working by myself).

 

[jwaller]

you should probably replace the rubber mounts while you have easy access to them. I did and I'm glad.

 

[wbdodgeiv]

I used a timber from the back of the cab through the open windshield. IMHO going across the doors makes getting in and out of the truck difficult and you have more place to wrench from above if you can open the doors. Just make a lifting eye with some angle and bolt to the xfer case top cover. And watch out for smashing brake and air lines that run along the frame rails, its very easy to do.

 

[Ord22]

This was my first job in the army, was to replace a transfer from a 2 1/2T. brings back the memories.