Having trouble getting the transfer case off

[tsi209]

Well im sorry mines is an auto

 

[92AWDHX40]

I just did mine after this reubild of the engine took a bit but i was able to pull it off and reinstall it two days ago.

 

[Boosted DSM 32]

While everything was out i took off the oil pan and every bar that was soaked in grease and oil and completely cleaned them all up and im putting a new oil pan gasket.. exhaust mani gasket.. oil return line gasket and anything else that coulld cause it to leak oil so she should be good as new and the car looks great underneath all cleaned up and not soaked in oil

Now were just waiting on the new throw out bearing to come in tomorrow so we can install the clutch and begin the reassembly and hopefully have it done by friday or early sat morning.. how long would you guys recommend the break in period on the new clutch?

 

[toppertopper]

Most clutchs have a paper that tell you how many miles 500-1000 miles depending on the clutch

 

[synthetek]

While everything was out i took off the oil pan and every bar that was soaked in grease and oil and completely cleaned them all up and im putting a new oil pan gasket.. exhaust mani gasket.. oil return line gasket and anything else that coulld cause it to leak oil

Make shure you change the crush washers on the bolts that hold the return line to the oil pan too - MF660031 Crush washer

how long would you guys recommend the break in period on the new clutch?

Depends on what kind of clutch it is.

 

[T is for TURBO]

Well im sorry mines is an auto

Makes perfect sence! I just installed mine Sunday with five bolts, and your comment had thrown me for a loop. I guess I've never personaly seen an auto t-case.

 

[Archer Fabrications]

Nice man! Yea after you do it a couple times, it will go a lot quicker.

i'm about to put my trans on for the 2nd time, it does become easier, except getting the dowels to line up is a PITA!!!! thats the only part i dread. im happy that this time its a built shep stage 3! ironic the stage 3 takes 3 weeks to make though. im stoked, doing a full engine bay clean up and simple green, mild tuck, strut tower bar install and coil pack relocation

glad you got it out!

 

[PieEyedPiper]

While everything was out i took off the oil pan and every bar that was soaked in grease and oil and completely cleaned them all up and im putting a new oil pan gasket.. exhaust mani gasket.. oil return line gasket and anything else that coulld cause it to leak oil so she should be good as new and the car looks great underneath all cleaned up and not soaked in oil

Now were just waiting on the new throw out bearing to come in tomorrow so we can install the clutch and begin the reassembly and hopefully have it done by friday or early sat morning.. how long would you guys recommend the break in period on the new clutch?

Consider using sealant instead of a gasket for your oil pan.

I'd give a plain-jane organic disk a solid 400-500mile break-in. Many get away with less.

 

[Archer Fabrications]

Use permatex "the right stuff"

 

[Boosted DSM 32]

Ok guys so i got everything in and started it up and the linkage or something feels compleltly off when i move the shifter around it feels so unnatural and something has to be messed up..

I used the 90 cables with the 91 trans and i know there a little different but i adjusted them all the way out and everything but it still feels so messed up and just not right when i go to put it in what feels like 1st i think its in 3rd and reverse wont go in at all

 

[T is for TURBO]

Here

 

[92AWDHX40]

My transfer case was hard to get off at first i had to work a bit to get off, and to make it worse it was hot on my garage floor. Finally it came off, had to replace some seals while i was there.

 

[Boosted DSM 32]

Here

Ok so now im confused some guys were saying you have to change the cables and shifter bracket and others are saying only trans mount.. i did the trans mount and everything is totally out of wack im definately thinking that im going to need cables..

Also i have my shifter cables adjusted all the way out and i think that is also messing with how sloppy it feels and how unnatural it feels.. im gonna try and find a part out 1g around me and grab the cables off of it.. Oh!! and just wondering since i have the 23 spline t case in now can i use any 23 spline transmission? would one off a 2g work if anything ended up happening and i would have to swap trans again

 

[Boosted DSM 32]

Hey guys.. i got the new shifter cables in and the car is shifting perfect and riding good, but now for some reason im only hitting 11 psi and you can hear a leak coming from somewhere and when the bov goes off its loud as hell like its not recirculated but it is! and everything is tight and just how it was?.. there has to be a big boost leak somewhere ALSO the car is idling a little rough and when in boost it just doesnt want to go.. i think it might be somewhere around the bov but idk why it would i never touched it and everything is hooked up correctly

 

[turboglenn]

Read my thread on tips for shimming and others posted here in the drivetrain, you'll discover the best way to do a trans (especially for a crippled up DSM'er like me who's always in pain is to ue a chain hoist, that way it hangs and you can angle, push pull or what ever with out having to support it's weight or worry about the jack making itsit funny

As for the T-case, mine is relatively tight on there when i have to remove it (have to today because i butchered the left CV int. shaft seal on the starter plate install the other day.

But i just put a large flat head towards the rear and wedge it a little, then do the same to the front of it and then it wiggles off by hand..... good cables and more so the correct cables and shifter for your trans make a huge difference, it's mainly a concert in 90 cars getting newer trannies, but even on my 2g i busted a 97 cable and replaced them with the 95 cables from my donor car and the shifting changed a bit in feel, and as ffar as i know the 95 cables are now supercede3d by the newer 97 style and up.

Another thing, make sure there's NO bends in the linkage that bolts to the trans that the cables hook to, i had a slight downward bend in the one the bolts on with 2 twelve MM bolts and the trans shifted like crap, I replaced it with the good one from my old trans and things got 100 times better

 

[T is for TURBO]

Oh!! and just wondering since i have the 23 spline t case in now can i use any 23 spline transmission? would one off a 2g work if anything ended up happening and i would have to swap trans again

No, you can go up to a 95-96 trans, but you cannot use a 97+ trans, unless you swap out the front diff ring gear or the output shaft.

-Shawn