Transfer case is leaking on the truck in sig. I have tried new seals for the output shaft, to no avail. It is leaking from the case halves. Has anyone else had this problem? The thing I want to know is if I can pull the rear cover off with the case in the truck, or am I going to have a bunch of parts spring out on me? I can get it apart and re-seal it, but I dont want a bunch of parts on the ground...

 

The very rear tail housing you can pull off and reseal without worry of parts flying out. Any other case half you do have to worry. It is not a hard case to work on.

 

I have had the extension housings for the rear output off, I need to get the case split in half now to reseal it.

 

Yank it out of the truck its really easy. I pulled mine out today it took maybe a half hour to do. The case is easy to split and everything is very straightforward when you have it on a bench. I had never been inside one of these before today and I had no probems figuring it out. Later, Blair

 

you can do it in truck the only thing you may heve trouble with is the oul pump and pickup

 

oil pump and pickup eh? What exactly is gonna happen here?

 

nothing much the oil pump fits snug on the splined shaft and it's easy to drop the pickup tube when putting it back in

 

take it out!!!!!!!!

its easy, just the driveshafts, shifter linkage, a vacuum plug harness, and 6 bolts.

sit it on the workbench and remove the 4 bolts holding the tail shaft extension on, remove it.

take the snap ring off the shaft thats resting on the bearing, then unbolt the case making note of the length of the bolts and their location.

now you can lift the rear part of the case off with the oil pump attached and pickup should stay attached to the pump.

now clean and reseal with a good quality RTV, the reassemble

 

02.5 here so no vaccum BS. What position should I have it in when I take the rear cover off on the bench? Sorry for the detailed questions, I have never taken a chandrive apart before. Had a dana 20 and 300 apart before during a jeep adventure, but no chaindrives.

 

use a block of wood and sit it up with the tailshaft pointing up, that way everything lifts straight up and off, and nothing falls