I have a broken transfer case, and need a diagram.

[Grleaf]

Hi,

I bought a used transfer case from someone and they said it was from the same vehical which is a 1997 ford explorer sport.
Now the problem is the front shaft has a U-Joint on the transfer case it has a knuckle deal I believe it's called a slip joint.
Yet the transfer case I got from that guy it has a U-Joint I was told it was probably a CV output flange where the knuckle should be.
The question is can I remove that U-Joint part and put the knuckle part there?
Both transmissions are identical except for this little issue.
Please Let me know any help would be apprieciated

Thank you ahead of time
Ron

 

[97sprt4x4]

could you possibly post a picture? that may help with helping you out.

 

[IZwack]

What you need is a transfer case with a "CV" front output flange - which I think existed from 97 on up. The transfer case you bought has a "double cardan" front output flange which I think came on the 95-96 Explorers.

You can probably swap the output flange but to be honest, I dont recall how the "CV" flange is held on. The double-cardan one is easy because it has one main large nut holding it on.

 

[Grleaf]

yea I PB blasted the nut with the U-Joint so it will make it easier to take off that nut
The other one i'm not sure where you take out the 6 bolts holds it together where it can be sperated which me and my brother took a screw driver to try to seperate it.
It is showing sighns of seperating but i'm haven a problem dropping the transfer case lol.
It's that top bolt on the passenger side that i can't get to.

 

[97sprt4x4]

yea I PB blasted the nut with the U-Joint so it will make it easier to take off that nut
The other one i'm not sure where you take out the 6 bolts holds it together where it can be sperated which me and my brother took a screw driver to try to seperate it.
It is showing sighns of seperating but i'm haven a problem dropping the transfer case lol.
It's that top bolt on the passenger side that i can't get to.

That bolt is a *****, your best bet is to get a big extension, or get a younger sibling/child and have them reach up there. it was a very slow process when i had to replace mine. getting it up there without a lift is much more fun

 

[BrooklynBay]

Welcome to this forum! I've renamed your thread, and moved it into the transmission & transfer case section.

 

[Grleaf]

well that's where i'm lucky caus i don't have a lift just a couple ramps so i'm so excited that i can barely contain myself
I'm figuring that i'm going to do a couple exntions and knuckles.
I emailed the guy i got the transfer case from tonight and asked if he still had the driveshaft so i can possibly replace it with mine.
The only problem is he told me it came out of a full sized explorer but everyone told me it's the same between the transmission and the transfer case as all the rest of those from 89 upto 2001

 

[gijoecam]

I'm not sure what he means by a 'full sized Explorer' as they all came in but one size.

As for the t-case, if yours is a 97, the only direct swap will be another one from a 97. The 97 needs the speed sensor on the rear output but has the fron CV output flange. If yours has a u-joint front output, the case came out of a 95/96. Unfortunately it'll probably make a little more road noise due to the double-cardan joint on the end, but it *should* bolt right up.

Swapping front outputs would not be fun... There are some internal differences that may or may not make them compatible. To my knowledge, nobody has ever tried it.

 

[97sprt4x4]

I'm not sure what he means by a 'full sized Explorer' as they all came in but one size.

he has a sport and he would be referring to a 4 door as "fullsize" i would assume