Thread: transfer case removal and re install easy??

Cut the heads off two M10 by 200mm long bolts, install these in place of two case-to-box bolts. They guide the transfer case in place without seal damage.

There is also a cradle you can fab up to allow a trolley/trans jack to hold the case level. It attaches to the sloping cover plate bolts. Easy to make out of a few scrap steel bits.

If you are doing it by yourself definitely use the long bolts and jack cradle. They are very heavy and there is no way you could install one by yourself any other way.

This is a simple job although quite a big one, lots of bits to be removed. I have done this 3 times in recent weeks what with swapping transfer cases from one vehicle to another. A trolley jack with a good lift height is a must, the cradle would be handy but not totally necessary if you have someone to maneouver the jack for you. Very difficult job to do on your own, but I managed it easily with my teenage daughter operating the jack.

Take the input seal out of the case, slide it on the shaft and only push it into the case when everything is about to slide together.

Otherwise you'll roger the seal and it will leak.

I've done it twice now with the use of a hoist, would hate to do it under ramps. for me it was the fiddly bits that made it hard more than the actual spanner spinning. I need to do it again to get to the govenor to pull it off and get it serviced so that I have proper gear changes - I didnt flush everything properly after smoking the last gear box and I have partially blocked the ports so now I have lost 4th with out lock up and also until she gets warm holds first for a long time.

Given what a job it is I would say $600-00 was reasonable

Would be good if someone could post a photo of there bracket.