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Old 12-20-2009, 06:53 PM   #1 (permalink)
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Transfer case removal??? How to??

Can any one tell me how to remove the t case from my 2003 2500?? I'm in the middle of doing an index ring and can't get the t case off.
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Old 12-20-2009, 07:11 PM   #2 (permalink)
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Jack and block under the trans to hold the weight , remove both drive lines. On the rear one take down the carrier, unbolt the line at the differential and don't pull the line out of transfer case or you will lose all the oil. mark both ends with paint or crayon so they go back together the same.

Remove the cross member, and transmission mount.

There are six nuts between the transmission and t-case. Remove them, have a jack under the t-case and a few taps with a dead blow hammer and a little prying and they fall apart.

Good luck, an extra set of hands makes it much easier.

BOWKILL
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Old 12-20-2009, 07:22 PM   #3 (permalink)
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Quote:
Originally Posted by BOWKILL View Post
Jack and block under the trans to hold the weight , remove both drive lines. On the rear one take down the carrier, unbolt the line at the differential and don't pull the line out of transfer case or you will lose all the oil. mark both ends with paint or crayon so they go back together the same.

Remove the cross member, and transmission mount.

There are six nuts between the transmission and t-case. Remove them, have a jack under the t-case and a few taps with a dead blow hammer and a little prying and they fall apart.

Good luck, an extra set of hands makes it much easier.

BOWKILL
ok that what I thought, I have everything done up to the part with the dead blow hammer. it just wont budge??
it seems to be seized on or something.

it there any specific way to take it out??
like does it need to be in neutral or something like that?
someone mentioned to me that if its a chain drive the tension on the chain need to be released before taking it down??

any ideas??
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Old 12-20-2009, 10:12 PM   #4 (permalink)
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if you removed the 6 nuts holding it to the tranny it will come loose. you need to wiggle it and pull sometimes they stick
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Old 12-20-2009, 10:47 PM   #5 (permalink)
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Just had mine out today, we didn't even need a hammer. Once we had all the bolts out we just wiggled it and it slid right out.
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Old 12-20-2009, 11:14 PM   #6 (permalink)
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That's what I thought, so mine must really be stuck then.
Any ideas to get it out??
I soaked it in WD40.
I don't really want to hit it to hard because it's aluminum and I think heating it is out of the question as well for the same reason.
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Old 12-21-2009, 08:47 AM   #7 (permalink)
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A few taps and a small pry bar is all that is needed. Make sure you have all six nuts off. No heat no WD-40

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Old 01-18-2011, 09:15 PM   #8 (permalink)
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im having the same problem on a '94 5spd manual. for some reason mine wont budge either! all 6 bolts are off. just seems as if there is something binding. any ideas on how you did yours?
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Old 01-18-2011, 09:22 PM   #9 (permalink)
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use a pry bar and wiggle it. should come apart real easy or at least on my last 6 trucks it did.
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Old 01-18-2011, 11:41 PM   #10 (permalink)
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the out put spines on trans. can get dry and rusty just need a little persuasion and Patience.
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Old 01-18-2011, 11:43 PM   #11 (permalink)
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Make sure you got all the bolts. Some are kind of hard to get too and kind of hidden
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Old 01-19-2011, 12:05 AM   #12 (permalink)
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the tcase and OD unit are made of dissimilar metals and corrode together , they changed one or the other in 2003 because the older ones don't seem to do it like the 03 and newer ones
look on the passenger side there is a gap you can get a big screw driver in , pry a bit then goto the drivers side with a big plastic hammer and give it a couple smacks where the front shaft bolts up... go back and forth a few time and it should come loose
I do it all the time at the trans shop I work at
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