Odd question, is this do-able?

[ghost30]

So here's my question. Several months back I purchased a new-to-me transfer case from my nearest junkyard, brought it home, but never seem able to devote the needed time, in one chunk, to replace it. I've read various things on here, I've looked up YouTube videos, I've talked to guys at parts stores and friends who are good with vehicles, and everything seems to point differently from everything else.

When I got the case, apparently the guy who pulled it decided to just cut the wires to the sensors instead of actually disconnecting them properly. This doesn't surprise me a bit, he did the same thing with the power door to a Buick a couple years back, sawing through all the wires with a Sawzall blade in -35*F.

One friend tells me there's needle bearings, which don't sound like something I want to mess with. But, those sound also like they're inside completely which, if I'm not rebuilding, just replacing, means I shouldn't have to fiddle with them? I think? My mechanic tells me it's a $200+ job, counting fluids... that's a bit rich for my wallet to eat. Other advice has basically been to lift it, pull the support, pull the old one and put the new one back in, and rewire it.

So, here's the question. Since this is my daily driver for work, and since my boss is a pr*ck who balks if you need him to do anything besides sit behind his desk and read his paper, I can't have the vehicle out of commission for more than 48 hours total. I also lack the adequate tools that a high-end gearhead or dedicated mechanic would have... I have most basic hand tools, including ratchets, sockets, wrenches, and a few other types of tools, but no power and no pneumatic tools. No lift, just jack stands and ramps. With these limitations, would it be possible to replace this, "in stages"?

What I mean by that is, one weekend pull out the old TC and disconnect the wires; the next, bolt the new one in place; the next, rewire it the rest of the way; and the last weekend, to do new fluids? Would it damage anything either in the transmission, TC or anything related, to have it attached but not connected? Or would I be better off waiting until next tax season and just eat the $200+ repair bill so I can finally have proper, working 4x4? I wanna get this thing muddy, dammit! Lol!

Thanks for any help yall can offer me.

 

[RangerX]

Why do you want/need to replace your T-case?

I swapped out my auto case for a manual in one afternoon, and I am by no means a mechanically minded guy. It's a very non-complicated swap. I'd rate it 2-4 hours if you've never done it. Start it on Saturday, even if things don't go smooth and you don't finish in a day, you can finish on Sunday.

 

[ghost30]

The reason I need to swap it out is because something inside doesn't work, my mechanic verified it was shot. I don't know what part is bad.

I'm swapping one auto for another auto, so that's why I'm wondering how damaging it would be to do it in stages versus one big overhaul. Thanks for your feedback.

 

[RangerX]

I don't see a problem doing it in stages, but I think it will go way faster than you're thinking.

 

[Anime]

Your plans state you're thinking of pulling the current TC the first weekend, then installing the "new" one the next weekend. You can't pull out the TC and leave it out if you want to drive the vehicle - even in 2WD. The transmission connects to the rear driveshaft through the TC.

That said, it IS a very simple and non-complicated procedure you can do in a few hours, probably a lot less.

Put the front tires on the ramps, put the jackstands under the rear axle (assuming you have a jack to raise it), get under there and disconnect the driveshafts from the TC, disconnect the electrical plugs, pull the bolts holding the TC to the transmission, put the jack under the TC to lower it down, then take the "new" TC and reverse the removal procedure to install.

You should probably drain the "new" TC and fill it with new Dex/Merc ATF before installing it (makes it way easier), and I'd also suggest getting a new gasket for the TC/transmission connection from Ford, since chances are pretty good that the old gasket will tear apart upon removal, or just fall apart from age if it's the original.

You should also just swap out the electrical parts/wires/sensors that are cut from the "new" case while the cases are both out. Of course, if the "new" case doesn't work, then it might be that the original issue with the "old" case was just an electrical issue.

You might want to search around on the forum for 95-97 auto TC issues and solutions before going to the trouble of replacing it, it might be something minor that can be fixed without removing/replacing the TC. Even if it isn't, you can use the info and images on those threads to see how to replace/swap parts and what to do on the "new" TC before installing.

 

[vq5speed]

You can swap out TC all in one day no problem. If your not afraid to get dirty have the tools to do it. You'll need a floor jack an extra set of hands would be helpful if you have a friend. But its a doable one man job with a floor jack if you have no one to help.

 

[ghost30]

Okay guys sounds like a workable plan, I'm going to have a friend help me this coming weekend. I'll let you all know how it works out. Thanks for the feedback.

 

[ghost30]

Hey all, update time.

Went this past weekend to see if I could get it done, turns out nope. The salvage yard I bought it from fleeced me. Badly. First, it was the TC to a 96 they sold me, completely incompatible. Second, it was sitting on the shelf for several years marked at a hair over $75 and they sold it to me for well over $200. Third, it wasn't stock, someone had started modifying it. Fourth, one of the bands inside was about ready to let go. I'm not happy.

So, I guess I'm gonna try to sell it as is to someone who knows what they're doing, hopefully I can recoup at least something for it. Might be good in a rock-crawler or something, I don't know.

Figured I'd let you guys know what happened though. Thanks for the tips, maybe my mechanic can get it figured out at tax time.

 

[vq5speed]

Your yard wont take it back or exchange it. The yards here always takes it back or exchanges it if it doesn't fit or work. They mark the part when you buy it so they know its the same part they sold you. That blows if they wont take it back.

 

[Anime]

Yeah, take it back ASAP with receipt for a full refund. Don't take no for an answer. If they try to stick you with it and refuse to give your money back, I'd suggest contacting the consumer protection agencies in your state/area, and/or contacting the local media to see if they take an interest in consumer issues about bad local businesses. That kind of potential bad publicity usually makes business owners change their mind about certain things.

 

[ghost30]

I would take it back except for the fact I believe I bought it over three months ago and apparently the company likes to fleece people who aren't locals. Buyer beware I guess... I should have known it was going to cause a problem when I bought a power door for a 95 Buick lesabre and they literally cut through all the wires and told me to splice, in -35*f weather. Couldn't take ten seconds to find the wire bundle, just cut it apart.

Last time I'm ever doing business with them I think.

 

[vq5speed]

I would try anyways what do you have to lose.Tell them they sold you the wrong part. You didn't get around to doing the project till now. Tell them you just want an exchange no money back just want the right year. But since you opened it up they might not just for that unless you can make it look like you didn't..