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How do you remove a transfer case?

The1980BEAST

The1980BEAST

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So I decided I'm gonna try and tackle my T-case. I have a broken seal inbetween the T-case and the transmission. Problem is, I have no Clue how to remove my transfercase to get to that seal.

I tried looking on google and CK5 and couldn't find anything, maybee I'm just not searching in the right places :o.

Anyways I was just going to see if anyone knew a website or something that could explain how to remove it , maybee with some pictures or diagrams? Or if you yourself could explain...

Thanks,
Randy
 
Pull the drivelines, skid plates and cross member then support the case with a jack. Undo the bolts holding the case on and it will have to slide out about 6" or so then its out. Its not a very hard thing to do but they can be pretty heavy and akward especially the 205's and 203's. Good luck
 
If you are working on your `80, and it is the original t-case, you will have an NP205. Those t-cases are very tough, but also very heavy. You'll probably want a proper transmission jack to support it when you bring it down, and it'd probably be a good idea to have someone there to help you / keep an eye on you just incase it does fall and injure you.
 
The 205 is heavy, i pulled mine this winter and i would recommend atleast a transmission jack adapter on a 2.5ton. I would also chain it to the jack so if it tips over it should stay on the jack and off you.
 
An adapter for your floor jack would look like this

39152.gif


a transmission jack would look like this

39178.gif


or this

03185.gif


but my fave is still the ATV jack:

02792.gif


I've R&R'd a variety of tranny/t-case combos, including a a 350 with 203-205 Doubler. Due to the height of the truck there was some scrap lumber involved, and if you do that kind of stuff, you really should safety chain the thing (I didn't and I'm still amazed I have all my fingers =))

t-cases-in-4.JPG



-- A
 
I almost forgot if it is a np205 it might have an extra mount on the passenger side frame rail, it would just be 2 bolts into the case
 
jms said:
Support the transmission first. Once the crossmember is unbolted, nothing will hold the transmission up.
Click to expand...
You should only have to take off the rear crossmember so the front one, the one with the transmission mount on it, will still be supporting the transmission. Maybe its different on auto's but that is how it is with my 465:dunno:
 
NorCalKid said:
You should only have to take off the rear crossmember so the front one, the one with the transmission mount on it, will still be supporting the transmission. Maybe its different on auto's but that is how it is with my 465:dunno:
Click to expand...


what truck ever came with two cross members?
 
no pics no proof!! the 205 is a heavy mofo, i did mine by myself and it was pretty easy. just do a little at a time. i used an ATV jack and added about a foot of wood under it. i used 2x4s and just leveled it with the wood. i didnt strap it down, but its a damn good idea.

when you undo the last bolt it will swing down if its not fully supported.

dont forget to drain it :o
 
If you have the 465/205 combo that second picture of a tranny jack is a POS IMO. MY uncle had one (probably a cheapy but nonetheless a POS) and i went to use it. No can do. could barely even withstand the weight of the combo. All the weight shifted and it crumpled like crazy. the scissor part i mean.

I'd go with the piece that attaches to the regular jack or the ATV jack does wonders.

I've used the 2 floor jack method and it works takin it out but a PITA to put back in that way.

Good luck man ;)
 
Even with a good tranny jack, having a ratchet strap on hand can help balance things too.... both strapping the tcase to the jack and/or suspending part of it between the frame rails with the strap can really help the balance. With my limited skill and even more limited strength, I wrestled an assembled 203/205 doubler in place with a tranny jack and 2 ratchet straps last summer.
 
One side of the t case hangs down lower than the other. Use a tranny jack. Pump the jack up till the plate just touches the lower side of the case. Now, use blocks of wood, laid on the plate, to touch the high side of the case. Straps over the tranny, and around the plate, cinched down tight.

If you try it without straps, and the blocks, its probably gonna roll right off the jack. Be careful, those 205s can hurt you bad.:eek1:
 
I did this a little while ago and read a LOT beforehand. Everything said here is very helpful, but I recommend going and buying a Transmission Jack (like the one posted earlier)... the Scissor kind. It was cheap at Harbor Freight, and helped a LOT. Some comments:

1.) They aren't kidding that the transmission will swing down when you unbolt things. CAREFUL!

2.) Getting it out is easier than getting it back in. Without a transmission jack, I would have had a HECK of a time.

3.) I would get some really long bolts and use those as "guides" to line the tranny up with the transfer case and adapter. That helped me immensely when I reinstalled it.

4.) Be safe. Those things could easily crush your head, hands, arm, whatever. They are weirdly shaped, and can just decide to kill you it you aren't strapped down. Go slow, and be safe!

-Dan
 
Nice! Very creative! If you get bored with that, PM me and I'll take that off your hands. :)
 
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