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Transfer case removal - Cars & Trucks

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First remove both front and rear driveshafts. Then remove skid plate underneath transfer case. Remember to unplug the electric motor wiring harness for explorers with electronic four wheel drive switching. Remove vacuum line on the top of transfer case. Unbolt Speedometer cable mount from top/rear of transfer case. Remove five bolts connecting the transfer case to the transmission, this step will cause some transmission fluid to leak from the shaft housing (approx. half a litre) so place a drain pan underneath. Remember to either place a jack or wood blocking under transfer case before removing the last bolt connecting the transfer case as it is heavy (approx. 80-90 lbs.).

Posted on Aug 09, 2010

  • Ms Rain Nov 05, 2010

    I did all that, but the transfer case still won't come off the transmission, so how do i get it off?? Thanks

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Posted on Jan 02, 2017

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SOURCE: transfer case removal and installation

   You need to remove the skid plate/crossmember (6 3/4 bolts at the frame and 3 nuts at the trans mount.). Support the trans first with a jack and a block of wood before removing. Remove the rear drive shaft from the differential and pull it out of the transfer case. Unbolt the front shaft from the transfer case only and wire to the side with a coat hanger.Disconnect the vacuum connector from the top and the speedo cable. Unbolt the shifter and bracket (tricky operation). unbolt the transfer case from the trans and pry it rearward with a floor jack under it. Reverse operation to install. The 87 used a different case than the 231 from the factory but the 231 will work. You may have a concern with the length of the shift linkage. If you do anyone with a welder can extend it for you. Good luck hope this helps.

Posted on Oct 19, 2008

  • 1 Answer

SOURCE: transfer case diagram

i have the solutios contact me strokeproducciones@hotmail.com i have the diagram of transfer case, can i give you contactme. see you

Posted on Nov 21, 2009

  • 84 Answers

SOURCE: Leaking transfer case..

First of all yes it will damage the transfer case with no oil in it or even low oil. if it is just a seal then it is easy to replace, but if it means splitting the transfer case this is not a job for the diy, unless you have experience with transmissions or transfer cases. It should not be too expensive to have the work done by a profesional. Which also give you a warranty.

Posted on Dec 22, 2008

  • 15 Answers

SOURCE: Transfer Case Replacement? Cost?

that sounds too high to me.. check local junk yards for price first, then call a shop and ask them how much labor it is to install it..will be much cheaper....im a garage owner and the labor book is showing 2.1 hours to replace times their labor rate

Posted on May 16, 2009

  • 400 Answers

SOURCE: front drive shaft/transfer case removal 03 chevy trailblazer 4wd

Sounds like you got it. They are heavy and ocward (spelling?). As for the front drive shaft take the bolts out and give it a couple of wacks with a dead blow hammer then slide it out. Maybe a few days before hand give it a good spray down with wd40 or like product. Also when you get to the last bolt for the t-case to trans loosen it half way then put a drain bucket under it and seperate it a little and let the trans fluid drain some, or you will be wearing it.

Posted on Dec 23, 2009

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2001 chevy blazer transfer case removal


How to Remove a Chevy Blazer Rear Transfer Case The transfer case on a Chevrolet Blazer is underneath the vehicle, mounted to the rear of the transmission. On four-wheel drive vehicles, the transfer case takes power generated by the engine and channeled through the transmission and directs it to the front and rear drive axles. Over time, the gears and bearings inside the transfer case can wear and the transfer case must be rebuilt. The transfer case on this vehicle must be removed before it can be serviced.
Things You'll Need
  • Wrench set
  • Floor jack
  • Jack stands
  • Socket set
  • Masking tape
  • Marker
  • Needle-nose pliers
Hide Instructions
  1. Removing the Driveshafts
    • 1 Disconnect the ground cable from the negative battery terminal, by using a wrench to loosen the retaining bolt and pulling the clamp off the terminal.
  • 2 Raise the vehicle and support with jack stands placed underneath the frame.
  • 3 Drain the transfer case. Locate the drain plug near the bottom of the transfer case. Place a waste oil collection pan underneath the plug and use a socket to remove it. Once all the fluid has drained out, reinstall the plug.
  • 4 Remove the bolts that connect the rear driveshaft to the rear axle yoke using a socket. Lower the driveshaft, and slide it backward underneath the rear axle to disengage it from the transfer case. Remove it from the vehicle.
  • 5 Remove the bolts that connect the front driveshaft to the front axle yoke using a socket. Lower the driveshaft, and slide it forward underneath the front axle to disengage it from the transfer case. Remove the driveshaft from the vehicle.
  • Removing the Transfer Case
    • 6 Label and disconnect the electrical wires and vacuum lines connected to the transfer case. Use masking tape and a marker.
    • 7 Remove the transfer case shifter rod. Using needle-nose pliers, remove the clip that connects the shifter rod to the transfer case. Slide the rod away from the transfer case.
    • 8 Position a floor jack underneath the transfer case. Raise it enough to take the weight of the transfer case off the transmission.
    • 9 Remove the bolts that connect the transfer case to the transmission using a socket or wrench.
    • 10 Slide the transfer case rearward to disengage it from the transfer case. Lower the floor jack, and remove the transfer case from the vehicle

    Jul 27, 2014 | Cars & Trucks

    1 Answer

    How to remove transfer case from 2002 tahoe


    • Disconnect the ground cable from the negative battery terminal, by using a wrench to loosen the retaining bolt and pulling the clamp off the terminal.

    • 2

      Raise the vehicle and support with jack stands placed underneath the frame.

    • 3

      Drain the transfer case. Locate the drain plug near the bottom of the transfer case. Place a waste oil collection pan underneath the plug and use a socket to remove it. Once all the fluid has drained out, reinstall the plug.

    • 4

      Remove the bolts that connect the rear driveshaft to the rear axle yoke using a socket. Lower the driveshaft, and slide it backward underneath the rear axle to disengage it from the transfer case. Remove it from the vehicle.

    • 5

      Remove the bolts that connect the front driveshaft to the front axle yoke using a socket. Lower the driveshaft, and slide it forward underneath the front axle to disengage it from the transfer case. Remove the driveshaft from the vehicle.

    Removing the Transfer Case
    • 1

      Label and disconnect the electrical wires and vacuum lines connected to the transfer case. Use masking tape and a marker.

    • 2

      Remove the transfer case shifter rod. Using needle-nose pliers, remove the clip that connects the shifter rod to the transfer case. Slide the rod away from the transfer case.

    • 3

      Position a floor jack underneath the transfer case. Raise it enough to take the weight of the transfer case off the transmission.

    • 4

      Remove the bolts that connect the transfer case to the transmission using a socket or wrench.

    • 5

      Slide the transfer case rearward to disengage it from the transfer case. Lower the floor jack, and remove the transfer case from the vehicle.


    Jan 20, 2012 | Cars & Trucks

    2 Answers

    How do u remove a transfer case


    Most suvs have the transfer case linked to the transmission. Best is to take both out at the same time.Generally:
    1. Disconnect the battery
    2. Unplug all wires from the transmission - transfer case unit. Make sure you mark them so you can reconnect them properly
    3. Get inside the car and remove the shift lever(s)
    4. Remove the starter
    5. Remove the clutch slave if there's one or disconnect all cables from the unit
    6. Support the car on stands so you can work easily under it.
    7. Drain the oil from the unit may have 1 or 2 drain plugs
    8. Remove the shafts making sure you marked the alignment where they are joined
    9. Support both the engine and the transmission unit with the appropriate jacks
    10. Unbolt the transmission from the engine
    11. Remove the unit support (s)
    12. Remove the unit from the car.
    Important to remember the type of oil that goes in the trans and in the transfer case. They may not be the same. Also, some electrical transfer cases don't use any oil.

    Oct 19, 2011 | 2000 Oldsmobile Bravada

    1 Answer

    Where is the transfer case shift motor located on 2004 dodge dakota


    The transmission control module and the transfer case control module are separate parts. The transmission control module is mounted under the hood and controls only transmission functions. The transfer case control module controls only the transfer case, and is located inside the truck. If you remove the trim panel under the steering column you will find the transfer case control module mounted just to the right of the opening.


    The shift motor is located just behind the axle tube to prevent damage.
    There is a shift motor on the right front axle that is vacuum operated.
    The shift motor (1) is an electromechanical device consisting of a DC permanent magnet motor, a motor brake, a gear train and an analog position sensor. The shift motors' overall function is to move and lock a gear that moves the mode fork found in the transfer case. This allows the transfer case to be shifted electrically to multiple operating positions (4LOCK and AWD). The operating current of the shift motor under
    stall conditions is 30 amps maximum at 72° F with 13.5 volts, at the motor leads.
    OPERATION
    Shifting in the transfer case occurs when the shift motor brake is released and a Pulse Width Modulated (PWM) voltage is supplied to the shift motor by the Front Control Module (FCM). A linear analog position sensor located inside the shift motor, provides the FCM with the motors' angular, rotational position. With this information, the FCM
    continuously knows the motors' position, and therefore allows it to accurately control the motors' operation, including voltage polarity which is used to control motor direction.

    REMOVAL :---Note: New shift motor assemblies are shipped in the AWD position. If a new shift motor assembly must be installed, it will be necessary to shift the transfer case to the AWD position prior to motor installation.
    Raise the vehicle on a suitable hoist.Remove the front propeller shaft. Disengage the wiring connectors from the shift motor and mode sensor.Remove the front output shaft companion flange from the transfer case.Remove the bolts (Remove the Shift Motor and Mode Sensor Assembly Bolts) holding the shift motor and mode sensor assembly onto the transfer case.Separate the shift motor and mode sensor assembly from the transfer case. See fig below:-- helpmech_19.gif
    1 - TRANSFER CASE.2 - SHIFT MOTOR AND MODE SENSOR ASSEMBLY.3 - BOLT.-- This should help.Thanks.Helpmech.

    Feb 26, 2011 | 2004 Dodge Dakota

    1 Answer

    Transfer case removal


    Suzuki Samurai/Sidekick/Tracker 1986-1998 Repair Guide
    Transfer Case Assembly - REMOVAL & INSTALLATION

    Samurai Models
    Even the 2WD Samurai uses a transfer case. Rather than use a straight line driveshaft from the transmission to the differential, the Samurai leaves the transfer case in place and replaces its internal working with a simple offset gear mechanism, thus keeping 2 of the 3 driveshafts used in the 4WD vehicle.
    1. On 4WD vehicles, remove the transfer case shift lever.
    2. Raise and support the vehicle safely.
    3. Drain the oil from the transfer case.
    4. Matchmark and remove the driveshafts from the transfer case assembly. Not all of the driveshafts need to be completely removed from the vehicle, just unbolted from the case flanges. In most cases, the shaft or shafts on one side of the transfer case can be repositioned and supported out of the way.
    5. Support the transfer case using a suitable transmission jack.
    6. Disconnect the speedometer cable from the transfer case.
    7. On 4WD vehicles, disconnect the 4WD switch lead wire at the coupler.
    8. Remove the three mounting bolts and/or nuts securing the transfer case to the chassis, as applicable.
    9. Carefully lower the transfer case from the vehicle.
    To install:
    1. Position and install the transfer case. Tighten the mounting bolts to 159-248 inch lbs. (18-28 Nm) and/or the mounting nuts to 19-25 ft. lbs. (25-34 Nm).
    2. On 4WD vehicles, connect the 4WD switch lead wire at the coupler.
    3. Connect the speedometer cable to the transfer case.
    4. Properly refill the transfer case with an approved type of gear oil.
    5. Align and install the driveshafts to the transfer case.
    6. On 4WD vehicles, install the transfer case shift lever.
    7. Remove the jackstands and carefully lower the vehicle.
    Sidekick, Tracker, Sidekick Sport and X-90 Models
    On these models the transfer case is bolted to the transmission and takes the place of the 2WD transmission's extension housing. Therefore, transfer case is removed or installed as part of the transmission assembly.

    Hope this help (remember rated this and comment).

    Mar 21, 2010 | 1993 Geo Tracker

    2 Answers

    HOW TO DISCONECT THE TRANSFER CASE ON A 2002 FORD EXPLORER 6CYLS


    remove the front and rear drive shafts and remove the bolts from the transfer case around the transmission the transfer case will then slide backwards and off of the transmission

    Feb 09, 2010 | 2002 Ford Explorer

    1 Answer

    I need to know how to install a rear drive chain on a 1992 ford bronco. It's in the transfer case and only drives in 4 low now. The mechanic said its 4 bolts to the transfer case and the chain is right...


    It has more than four bolts. You have to remove the drive shaft and all of the linkage from the transfer case including any electrical connections. You can then remove all of the bolts connecting the transfer case to the transmission. After all of the bolts have been removed just remember due to the angle the transfer case is mounted it will try to twist when it is disconnected from the transmission. And keep in mind that the transfer case is HEAVY. Truthfully if you are not a pretty fair mechanic you might want to have a qualified technician do the job for you.Some of the transfer cases Depending on which transfer case you actually have, some of them can be a real pain in the neck to install a chain.

    bigc

    Jun 29, 2009 | 1992 Ford Bronco

    1 Answer

    Pictures of removing gearbox and transfer case from vehicle


    REMOVAL & INSTALLATION CAUTION
    The catalytic converter is located beside the transfer case. Be careful when working around the catalytic converter because of the extremely high temperatures generated by the converter.
    1. Disconnect the negative battery cable.
    2. Raise the vehicle and support it safely.
    3. If so equipped, remove the skid plate from frame.
    4. Drain the transfer case.
    5. Remove the damper from the transfer case, if so equipped.
    6. On electronic shift models, remove the wire connector from the feed wire harness at the rear of the transfer case. Be sure to squeeze the locking tabs, then pull the connectors apart.
    7. Disconnect the front driveshaft from the axle input yoke.
    8. If equipped, loosen the clamp retaining the front driveshaft boot to the transfer case, and pull the driveshaft and front boot assembly out of the transfer case front output shaft.
    9. Disconnect the rear driveshaft from the transfer case output shaft yoke.
    10. If equipped, disconnect the speedometer driven gear from the transfer case rear cover.
    11. If equipped, disconnect the electrical wire harness plug from the Vehicle Speed Sensor (VSS).
    12. Disconnect the vent hose from the mounting bracket.
    13. On manual shift models, perform the following:
      1. Remove the shift lever retaining nut and remove the lever.
      2. Remove the bolts that retains the shifter to the extension housing. Note the size and location of the bolts to aid during installation. Remove the lever assembly and bushing.
    14. If equipped, remove the heat shield from the transfer case.
    15. Support the transfer case with a transmission jack.
    16. Remove the mounting bolts retaining the transfer case to the transmission.
    17. Slide the transfer case rearward off the transmission output shaft and lower the transfer case from the vehicle. Remove the gasket or any old sealer from between the transfer case and the transmission.

    Mar 29, 2009 | 1988 Mazda B2600 Cab Plus

    1 Answer

    Auto trans 4x4


    Oh lord, are you in for some work. First of all you will need a transmission jack, a must and a couple of strong guys if you don't have a lift. First things first. Disconnect neg. bat. cable. Raise up on jack stands. Disconnect drive shafts and tape bearings caps on drive shafts. Remove Starter. Disconnect wiring harness plugs from transmission and transfer case. The wiring harness connection on the shift linkage does not remove. There are 2 connectors and are glued at factory. Remove whole shift linkage unit from side of trans. Remove exhaust. Remove dust cover. Mark spot on flywheel and tourque converter, then remove bolts from flywheel. Support trans. with jack. Remove transfer case bolts from trans. Remove mount nuts from transfer case bolts. Remove bell housing bolts from motor to trans. Remove bolts from crossover support for transfer case mount from the main frame. Raise up transmission and remove crossover support. One guy now supports transfer case and other works transfer case loose. The transfer has to be jockeyed around until it drops out. It will not come straight out or down because of the tor. bar support frame. It has to be wiggled out and down. Guy supporting transfer case gets trans fluid bath and this is all muscle work. With transfer case out, put another jack under motor for support or risk breaking motor mounts and other things. Slide transmission back and lower down and its free, It is a very dirty, oily, nasty hard job. I just went through it. I wouldn't do it again. If you can afford it, take it to a pro. Well worth it. Remember once started, your pretty much commited. Reverse the whole thing to install. Good Luck

    Feb 01, 2009 | 1999 Chevrolet Silverado 1500

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