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t case swap

digglesworth

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
Got my 4:1 t case ordered and I've got a couple questions. Looks like the front shaft just unbolts. What about the rear? I've never taken u-joints apart. Looks like there's some clips involved in the round holes that may have to come out..... Also, there's a cradle on the bottom of the case that sits on the cross member. Does that swap over to the new case? Do I leave it on the crossmember and unbolt the case from it or pull it out still connected to the case? Also, it should come with a new encoder motor. Is this plug and play where I just plug the new one in or do I need to use my old one? Is it matched to the vehicle somehow where the new one wouldn't work? Other than that, its just the ring of bolts connecting it to the trans holding it in there, right?
Also, does anyone have the part number for the gasket that goes between the t-case housing and transmission housing?
 
Bigunit

Bigunit

Hammer Down!
Staff member
Messages
6,561
Location
Arizona
The gasket part no. is15642511. You will need to remove encoder motor to get the TC in to get it to slide back a bit and onto the crossmember.
 
CaseyS

CaseyS

Well-Known Member
Messages
755
Location
Louisiana
1. Pull front driveshaft. Remove the 4 bolts holding the cv to the front flange. Note, these are loctited on from the factory, you may need some heat the first time these are removed. Push the shaft out of the way. No need to disconnect from the front pumpkin.

2. Pull rear driveshaft. 4 bolts on the rear u joint clamp. Pull the rear driveshaft out of the yoke. You may have to undo 2 bolts and roll the vehicle back to get the other 2. MAKE SURE to set the parking brake and chock the wheels during this process!

3. Pull the encoder motor. 4 10mm bolts. Disconnect the electrical connector.

4. Remove the VSS connector. Remove the vent tube if you can reach it.

5. Remove the 5 bolts holding the xfer case to the transmission adapter. I think they are 15mm and a swivel socket and a box wrench to remove the nuts.

6. I find its easiest to sit perpendicular to the truck with your head out to the side under the rear driver door. If you sit on your ass, bend your knees with your feet on the floor, you can support the weight of the case on your upper thigh. Push the case to the rear and let the crossmember catch the weight of the tail as you support the front of the case as it comes off the yoke. Front end downward and slide the tail off the crossmember and lower the case on your legs.

Installation is reversal of removal. Might want to fill the case before you put it in. Much easier that way. Ive never drained the case before removal and have not had any spill issues.

Edit: dropping the transmission cross member makes it easier to get to the trans to xfer case bolts. Be sure to support the weight of the transmission with a jack and a board under the trans pan. Unbolt the case from the 5 bolts at the rear of the trans adapter, not the 6 bolts from the adapter to trans
 
Last edited:
digglesworth

digglesworth

Well-Known Member
Messages
1,789
Location
illinois
Thanks Casey... On step 2, once the rear drive shaft is seperated from the rear diff, does it just pull out of the transfer case like a cv shaft in the front axle?
 
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