Transfer Case Removal

[sherwinz28]

Is it possible to remove the tranny with the transfer case attached? I can't remove the transfer case from the transmission. I took all 5 bolts out and it seems like its stuck to the transmission. I've pryed at hit, hammered, pryed some more and it still won't come out. I notice the rear part closest to the driveshaft will give a few centimeters of leway but the front won't budge at all. Is it possible to remove them together as one piece? If so how do I go about doing so? I've already removed every bolt holding the transmission to the engine.
92 Talon TSI AWD turbo.

Thanks,
Sherwin

 

[1fast97gsx]

no it's not really possible.

 

[shorty_du_op]

There's 6 bolts holding the transfer case on

 

[hewhoisknot]

There is one all the way on the top tucked in a little bit. That's the one i always miss. Just feel around.
BUN

 

[sherwinz28]

There is one all the way on the top tucked in a little bit. That's the one i always miss. Just feel around.
BUN

I got that one out. There should only be 5 unless I somehow through my searching didn't see the 6th one?

 

[shorty_du_op]

There are 6!

 

[akdsmer]

To be help out....(although not real clear)

 

[sherwinz28]

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Ok well I've removed the bolts marked in white there...where is the sixth bolt? Is the sixth bolt just a pin that the transfer case hangs from?

 

[TimG]

There are 5 bolts and a locating pin. It should slide off the shaft once the bolts are out.

 

[Doug99RS]

There are 6!

If you feel as though there are 6 we encourage you to post pictures to support your claims. Thanks,
Doug

 

[FastEclipseGSXT]

there is only five bro, sounds like alignment pin is jamed, it should come off with some finagling, might want to give it another try, i wouldnt hammer it anymore though, just pry and wiggle

 

[sherwinz28]

Just thought I'd let you guys know I finally got it off. I had to pry and wiggle it for like 30+ minutes and it finally came off. It looks like there was some rust on the gear coming out of the transmission to the transfer case. I also pounded with a screwdriver on the backside of alignment pin, not sure if this helped but I was able to get it off afterwards. In any case I then removed the final bolt in the back of the tranny and pryed that off the block as well. I'm definately an amatuer mechanic and it took me about a week to finally get this thing off...of course I only spent like an hour or so a day trying to remove it. Without dsmtuners I'm not sure I'd be able to do all this stuff.

Thanks again.

P.S. It is only 5 bolts!!

 

[hellotbone]

There are 6!

 

[4pistons]

It looks like there was some rust on the gear coming out of the transmission to the transfer case

That sounds like a center diff problem that is wearing your splines. If you don't fix it soon it may fail. Look at the splines, are they worn and shiny? I'll bet that shaft isn't rusted. What you are seeing is rusty iron dust from the splines wearing off. Grab the output shaft and move it in and out. If it moves more than a few thousandsth you've got center diff issues.

I went through TWO new output shafts before I realized how to correct the problem.

Rick - '91 GSX

 

[sherwinz28]

That sounds like a center diff problem that is wearing your splines. If you don't fix it soon it may fail. Look at the splines, are they worn and shiny? I'll bet that shaft isn't rusted. What you are seeing is rusty iron dust from the splines wearing off. Grab the output shaft and move it in and out. If it moves more than a few thousandsth you've got center diff issues.

I went through TWO new output shafts before I realized how to correct the problem.

Rick - '91 GSX

Doh! I was wondering why the output shaft that goes into the transfer case from the transmission would be rusty. I'll go home and check to see if theres play on that shaft. If there is play what is the next step?

Thanks

 

[sherwinz28]

Well I checked the shaft and there is no play at all.

 

[dsmcrazyspiff]

in and out play of your output shaft has absolutly nothing to do with your center diff
it does not mean your center diff is bad
dont make people worry for no reason

 

[4pistons]

in and out play of your output shaft has absolutly nothing to do with your center diff

It sure does! Take a look at a schematic or take one apart. The only connection of the output shaft is to the passenger-side side gear by the small retaining ball. Excessive sideplay is an indication that the side gear thrust washer is shot. All of that is IN the center diff.

If the output shaft is allowed too much endplay it will file off the splines on it's end and you'll go nowhere. I'm on my third output shaft because of a worn out diff.

Rick - '91 GSX

 

[dsmcrazyspiff]

sorry but i rebuild almost 10 a week i have built a trans for alot of people in here and i am telling u that u are crazy

 

[4pistons]

OK.... tell us what the output shaft is connected to then.

Rick - '91 GSX

 

[dsmcrazyspiff]

yes the output shaft splines mate up with the diff top but it is free floating the only thing that keeps it there is the little ball that is held in by your viscous coupler or if it is welded a locking collar so even if your diff is welded your output shaft will still move

 

[4pistons]

The output shaft is NOT free floating! If it was free floating it wouldn't be retained by anything. But it is retained by trapping that little ball with the VC to the side gear.

If the side gear thrust washers are in good shape and have no play the shaft will not move. If the thrust washers are shot, as many are in a DSM center diff, the output shaft will slide in and out, which it isn't supposed to do, and the splines that engage the x-fer case will file themselves down to failure.

Rick - '91 GSX

 

[yekrahs]

Ok I took out the 5 main studs...and I can pry the t-case from the tranny about a 1/2 inch but it will not come off something is keeping it from seperating? Any ideas I'm kind of in a hurry

 

[JayRolla]

Did you unhook the rear drive shaft? Also isnt there 6 bolts, been awhile since ive removed one cant remember

 

[yekrahs]

I didn't think you had to unhook the driveshaft? well I'll try that