Transfer Case Removal

[JayRolla]

Yea unhook the rear shaft and slide it off. Its probably not giving you enough play with it installed.

 

[wibblersnatch]

I never had to take my driveshaft off. It's probably stuck on the shaft coming out of the tranny. Mine did that, actually pulled the shaft out a little and lost some syncromesh. I ended up using a good pair of channel locks to hold the shaft and break it free from the t-case.

 

[yekrahs]

Alright I'm ganna try to use some channel locks thanks for the quick replies guys. THe only thing is I dont think I can even get channel locks between that gap its only like a 1/4-1/2" gap?

 

[AuntiesTSI]

I thought there were more than 5 bolts too?? But watch out when you're prying it off, my friend ate his T-case once

 

[GSX93DSM]

Yeah its like 5bolts. I did notice that the 90 tranfercase has aluminum frontcase while the 91-94 has cast maybe thats me just finding out but hey I just wanted to throw that out there.

 

[yekrahs]

alright I know it shouldnt be this hard to pry it off there has to be something seriously from keeping it from budging. Its like theres still a bolt in somewhere but I got all 5 out, theres a long and a short on the top, then two longer ones near the bottom and a short on on the bottom right so I don't know what I'm missing.....

 

[JayRolla]

Do you have a shop manual, just to make sure you doing it correctly. Mine came off with no prying at all.

 

[xveganxcowboyx]

I don't remember how many bolts there are, but I'd look really carefully. It's easy to miss one with the nooks and crannies on those things.

 

[Auto RS T]

There are only 5 bolts, if you can slide the t-case slightly then that means all the bolts are out, otherwise it would still be tight to the transmission. You do not have to pull the driveshaft first, simply lower the t-case and slide the shaft out. Be careful, the t-case is heavier than it looks.

I would grab the t-case near the tail and wiggle it up and down, side to side repeatidly. Then I would take a crowbar (being careful of the seal around the output shaft) and again try to pry it from the trans. Maybe two crowbars even, one on each side of the transmission shaft. You also have to be careful not to crack the t-case or the tranny in the process. Good luck.

 

[1990talon]

Yeah I thought mine was stuck to but then I just relized it fooled me it was heavier than it looks push up fairly hard then wiggle the back like stated above it should come right out.

 

[brute]

I cannot for the life of me get the transfer case out. I ended up having to drop the driveshaft and pull the motor with the tranny and transfer case connected. It supposedly has a 4 spider, but I don't know for sure, as the previous owner did that. I have unbolted all 5 bolts. I can get it to break loose and I have a gap all around. But it seems like there's still a bolt in it. I've checked, double checked, and triple checked everything. I've pried with screwdrivers.

I cannot get it to come off the spline.

 

[Lunch_Box]

There are only 5 bolt that hold it in place so you have them all out. Not really sure why it is stuck, all the ones I have taken off just need a good tug to get past the dowel pins.

 

[yokotabrat]

There was a guy locally one time that had similar symptoms. Apparently the output shaft had rust welded itself to the transfer case. The output shaft is fairly easy to remove. It's been a while, but from what I remember, there is only a ball bearing holding it in place. If you remove the end case of the tranny and remove the viscous coupler, you'll see the ball bearing. With that removed, the output shaft should slide out of the tranny hopefully with the transfer case still attached.

Bert

 

[1stGenRocks]

There was a guy locally one time that had similar symptoms. Apparently the output shaft had rust welded itself to the transfer case. The output shaft is fairly easy to remove. It's been a while, but from what I remember, there is only a ball bearing holding it in place. If you remove the end case of the tranny and remove the viscous coupler, you'll see the ball bearing. With that removed, the output shaft should slide out of the tranny hopefully with the transfer case still attached.

Bert

You should mention that this will only work after the tranny is seperated from the engine. Otherwise the tcase will hit the oil pan.

 

[DevilSperm]

Another possibility could be that the bearing is no longer holding the shaft in place and its actually moving with the t-case so no matter how far you pull it out, you'll never get it off. It's happened to me and its a pain to get the shaft separated if its rusted on there.

 

[yokotabrat]

You should mention that this will only work after the tranny is seperated from the engine. Otherwise the tcase will hit the oil pan.

Good call! With the extra length from the output shaft still being attached, the tranny has to be seperated from the engine. Forgot about that.

 

[brute]

It just sucks. I was hoping to have the head and block separated from each other and stripped by the end of yesterday. But I couldn't get the transfer case off, so I couldn't get the tranny off and I couldn't get the oil pan off. I'm really antsy to see the damage I have internally.

I was thinking the splines had somehow fused themselves to each other, which would be terrible. It's going to a tranny shop today to see if they have any tricks or special pullers for this type of thing. Hopefully it's nothing too big.

If the splines are fused together, how would I get the output shaft out of the transfer case?

Devil Sperm: how did you end up getting yours out? Muscle and prayers?

 

[yekrahs]

Alright still cant get this ####er out. its like still 1/2inch out but its like something is stuck? I dont know maybe I'm not pulling hard enough but I'm pulling and wiggling pretty damn hard. Any other suggestions would be helpful

 

[oldman]

Either it won't move at all, meaning you didn't remove all the bolts, or you're not pulling heard enough if it's already 1/2" out. Try tapping it from all sides using a rubber/wooden hammer.

 

[brute]

I'm having the exact same problem. My motor is completely out of the car and I can't do it. I have a post about it in Drivetrain Tech. The responses brought up a point that the transmission's output shaft can rust or fuse to the transfer case.

There are only 5 bolts.

 

[JayRolla]

Yea I didnt take of the drive shaft. I remember mine just pulled out and then I pulled it off the drive shaft. Thats a good point Brute, hopefully that didnt happen to him.

 

[DevilSperm]

I ended up wedging something between them to keep it out and then using some vise grips to push the shaft back into the tranny little by little. It eventually came out but it took an 1/8" at a time. I also PBed the hell out of it.

 

[sherwinz28]

I had similiar problems trying to get my transfer case out. It was stuck real good but I finally got it out.

http://www.dsmtuners.com/forums/showthread.php?t=201891

 

[yekrahs]

Ok I got it off but the input shaft is like binded to the transfer case how can I "unstick" these

 

[wishihadatalon]

To clear up the bolts that hold on the t-case confussion

IF you own an MANUAL awd dsm there are 5 bolts holding on your transfer case.

IF you own an AUTO awd dsm there are 6 bolts that hold your transfer case in place.

When pulling an auto t-case the shaft will come out super easy with the transfer case so you will need to find a way to seperate the 2 or you will hit the oil pan like stated before.

When pulling a manual t-case it should slide off of the shaft fairly easy. Judging by how hard it was for Jon at TRE to put my center diff and output shaft in, I doubt it will be coming out with the t-case. Use a large pry bar if its being a pain.

Also from what Jon at TRE explained to me and my own personal experience, if there is rust on your output shaft you will either want to clean it up and make sure there is good metal there or get a new one. You should use grease whenever you install it because the metal that they used for the shaft breaks down quickly if it gets rusty on the splines. I stripped my shaft out by just rolling into boost in 3rd gear (thankfully I had a welded diff so fwd for me