'94 XLT -can't get motor assembly back onto transfer case

[johnhon]

I removed the motor assembly on the transfer case of my 4x4 and am having a h--- of a time trying to fit the triangular pin on the case into the motor. Everything is oriented correctly, but it won't go. Am I doing something wrong or do I just need a bigger hammer? I already tried filing the pin a bit, but that didn't help. Thanks for any input.

 

[Brain]

OH MY!!!! DON'T FILE THE PIN!! It will cause too much slop in a situation where there is already too much slop (at least for my liking).

The three bolts (torx) that hold on the cover can be removed (mark an alignment mark first) and the gear inside can be pushed out from the back (where you see the female part of the triangle-ish pin)....do that, then put the four (normal) bolts that hold the motor and gear case back on (use some sealant to make it weatherproof), then put the large gear back into the gear case making sure you can see which way the triangle-ish selector is pointing. Then all you have to do is re-align the cover so that all the contacts are made at the right time (which should be where the match-marks you made before disassembling it match up).

 

[johnhon]

Thank you Brain. It worked like a charm and I'm now plowing through the snow, in a one horse open sleigh.. Merry Christmas. I love this forum...