transfer case removal

[brute]

Hey guys I need some help taking my transfer case off. First of all, I DO have a Haynes manual but I have trouble following the steps with this particular project. It says remove the 4 xfer case mounting bolts, which I did, but there were 5. It then says "pull the transfer case to the left toward the front wheel, then move it down and forward and carefully slide it off the front end of the driveshaft."

I understand this, but I cannot for the life of me do it. I have supported it with a jack, I have used a screwdriver to try to get in there to break the seal, but all with no cigar. I was, however, looking, and it appears to be gasket-ed with RTV or something of the sort. If I understand correctly, there is just supposed to be a paper seal, right? Could it be the RTV causing me this trouble of breaking it free?

Also, the Haynes says "remove the under cover (see transaxle removal and installation in Part A of this chapter)" What is this "under cover"? Do I need to take the transaxle off to drop the transfer case? Anyone with other helpful things to try so I can get it off and take off my balance shafts? Thanks!

 

[95blackGsTurbo]

There should be no gasket holding it on. Someone has taken it off before and thought it would be wise to use a gasket maker to hold it on. The only thing that should be holding it on is the 5 bolts. Looks like you are going to have to keep prying at it. Just make sure and double check that all bolts are removed. And no you don't have to take an undercover off. It should just slide off. Try wiggling the wheels to spin the shaft to see if the spline's are maybe stuck together and that might help loosen it.

 

[wolf20043]

^^^^^exactly. Sounds like it is just "glued" on with the RTV. As long as the 5 bolts are out, you should just have to keep prying at it to get the RTV loose.
Mike

 

[brute]

Thanks for the replies. So once I get it off, should I just scrape the RTV off both surfaces and then put it on with no gasket/seal or anything? Just metal on metal?

The previous owner had the 4 spider put in, must've been the guys he had do it put the RTV all over the place

 

[Quasimondo]

Just metal on metal, make sure you throw some grease on the transmission's output shaft and on the driveshaft yoke to help everything slide back in smoothly.

 

[ericbev]

Like stated above, once those 5 bolts are out, its just sitting on the bottom input shaft. A little elbow grease should get it off just fine.

A prybar will work better than a screwdriver. I got a whole set from small to gigantic for around $40. Tool purchases are always justifiable.

 

[95blackGsTurbo]

Got mine for $19.99 at Sears 4 different sizes.

 

[gmentals]

I recently removed my transfer case to replace the oil pan gasket. I recall that there were 6 bolts. Since you have the vr4 and I have a 2g, I dont know if they are the same. Just look around. Even after I had all the bolts out, it was somewhat difficult to pry. Dont forget to support the driveshaft with a wire or something. There was no gasket or sealant on mine. Be prepared to support the transfer case with something. It will fall off. Once I had pryed it about an inch and a half from the tranny, I got under it and slid it off. I kinda rocked it back and forth. Then slide it forward off the driveshaft. Good luck.

 

[Raynehr]

I just removed mine.. the front bearing in the front of the transfer case got burred up and hung on the bellhousing of the transmission, plus the two dowels, one upper and one lower, were holding her up pretty good. Myself and my dad just kept prying and pushing, she eventually fell off as pretty as you please.. take your time and you will be fine.

 

[turboholic]

http://www.vfaq.com/mods/transfer-print.html

 

[ereckerdeet]

Mine wouldn't come out either, 1g, had 5 bolts instead of hayne's 4 bolts. the output shaft was rusty from vibrations going on in there i guess but it had stuck itself to the splines in the xfer case. Just keep working it slowly, move your prybar around, and it should come off eventually.
good luck!
~E

 

[Dream On]

Just have two people under the car. You won't need a jack on it, even if its full of fluid. Its not THAT heavy. Have one person hold it while you pry it off. Its much easier than I thought it would be.

 

[BrokenTsi]

There's a perfect spot right under the transfer case to pry with a pry bar. You can slide it off easily. Sometimes you have to smash it with a rubber mallet to get things loose. But you can take it out with one hand, no need for a jack or other people to help.

 

[eclipsh]

FWIW, you don't need to pull the driveshaft or drain the t-case. Just leave the shaft in and make sure it doesn't slip out as you lower the t-case. All the fluid will stay in and everything will stay clean.

Also, were all five of the bolts you pulled the same diameter? 'Cause they should be. If not you may have pulled one wrong bolt.

Otherwise I umpteenth everything said above. Just get a pry bar (I used a tire iron) between the t-case and tranny and wiggle the bastard off.

You don't HAVE to use a jack to lower it, but it sure is nice. Sometimes getting the splines to match up when you are re-installing it is a bi*** and holding a full t-case/drive shaft above your head while lying on your back AND trying to wiggle it around gets real tiring after a minute or three.