Transfer case removal, can't get off, hits oil pan?

[gotboostsc]

I have a 92 awd automatic engine im trying to pull and im trying to pull the transfer case off. I have the transfer case seperated from the tranny but I cant slide the transfer case out all the way because it hits the oil pan... has anyone else run into this problem? I searched and no one mentions anything about taking the oil pan off.. the transfer case hits right where the oil pan begins to slope down.. We are going to pull the pan down and see if we can pull it out, but just wondering if anyone had this problem?

 

[MilwaukeeGSX]

I've delt with both 1g,2g (manual) transfer cases, niether have ever hit the oil pan. Take out the 5 bolts and pry with a flat head screwdriver. Slide it out evenly

 

[blownturbotsi]

Is the output shaft sliding out with the xfer case?

 

[gotboostsc]

Well actually this is a 93 but same anway, and there was actually 6 bolts.. but I mean I have it seperated from the tranny prob a good 6 inches and it wont come out further because of it hitting the oil pan.. I mean I can stick for example my thumb inbetween the transfer case and teh oil pan and it pinches my thumb..

 

[gotboostsc]

Is the output shaft sliding out with the xfer case?

Yea it is...

 

[gotboostsc]

Ok after searching in the forums for "output shaft" I see that a little ball bearing that is suposed to hold my output shaft in the tranny is missing.. So from what I understand the best way to fix this now is to remove the tranny end cover and take the VC off and some how try and hold the shaft in place while then attempting to remove the transfer case?

 

[blownturbotsi]

No you don't have to go through all of that trouble. My tranny is the same way and I can get my xfer case off just fine. All that I do is push the xfer case towards the tranny to push the output shaft back in, then you have to wiggle the xfer case a bit side to side. Most of the time I can get it off without wiggling, but just keeping it pretty much level while pulling on it. It takes practice, but it can be done without taking apart the tranny. Good luck!

 

[mach4g63t]

That shaft should just slide out of the transfer case and slip back into the tranny. My buddy's was doing that when we pulled out his manual t-case and we just slipped back into the tranny and dropped the t-case. Just slide it out of the t-case and back into the transmission and you should be good.

 

[gotboostsc]

So basically you guys are saying if I return the output shaft to its original location in the tranny, then wiggle the xfer case side to side and work it, it should relieve itself from the output shaft?

 

[blownturbotsi]

Yeah, and next time you put it back on, put a little bit of oil on the shaft and where it goes in the xfer case, they tend to get a bit rusty and it makes it easier the next time you have to remove it.

 

[The_EE]

+1 for lithium grease on the output shaft. Never have any problems with removing the transfer case, ever.

 

[gotboostsc]

Well honestly as soon as this engine comes out its goin in my fwd 5 speed.. so no more need for the auto.. but thanks for all the input guys, im prob gunna work on it again tonight and see if I can get it off.

 

[MountainDew]

Mine was hitting the oil pan as well. All you've got to do is a bunch of wiggling around and it should drop with ease. Just be forewarned its a little heavy, so be careful. I thought it was heavier then it really was and had a jack underneath it with my friend controlling it just incase.

Also be sure to tie the driveshaft to the car or support it with a jackstand.

 

[mister_n2o]

I've had this problem of the output shaft sliding wih the t-case on 2 1g autos so far. The easiest way to remove them while under the car is a large pair of channel locks and just have at it, it usually comes right off and you back in business.