Transfer Case Replacement

[jbillakdsm]

How hard is it to replace the transfer case on a 1g AWD and how much should I pay? I found a car for cheap and this is all it needs. Any suggestions? Is it ok if I find one in the junkyard that is in good shape to use as a replacement?

 

[ryan2987]

are you planning of buying the Black Talon AWD for the guy in washington PA. i was looking into buying that car. How much did you offer him for it? junk yard would be a good place to look but you got to get the 23 spline. its pretty easy to install.

 

[L2RTSiAWD]

Very Easy just pull off the DP and unbolt the T-Case.

Instructions right here:

T-case Removal

Later,

 

[jbillakdsm]

Ok, I found out that the worm gears inside are toast too. Are these hard/expensive to replace? I really need to do more research on the AWD system before I jump into this.

 

[L2RTSiAWD]

Not sure about that. I don't have any exp actually opening the T-case and the trans.

Later,

 

[NJGSX96]

I rebuilt my t-case a couple months ago. We replaced all seals, all bearings, necessary shims and the gears and it came to ~$200 in parts. You can find a used one in great shape for $150 so it is probably better to buy used, but I wanted a project to do so I rebuilt mine. Pulling it apart and putting it back together is relatively easy if you have some mechanical ability and something to press out the bearings but the pain in the butt part is the shims. Mitsu has like 10 different size shims and you won't know which one you need until you reassemble with the new bearings so expect some down time for that.