Replacing Transfer Case... What to expect?

[chrisb]

Hi there,

I just fixed the motor on my screwed up t-case and I going to put in a used t-case to replace mine that is making an awful clicking noise.

I've read in the Hayes manual about removing the t-case and it seems fairly easy. fluid, two drive shafts, five bolts, some wires. Is there anything I should expect that won't be straight forward?

Thanks for any help.

Chris Bright

 

[JDraper]

It's not too bad a job to do. Biggest pain in the a** when I pulled one was the bolts holding the driveshafts to the tcase. They are not standard bolt heads. You will need 12 point wrenches to do it properly.

 

[chrisb]

Thanks for the reply...

Did you change a BW 13-54 (first generatio explorer)? I noticed you had a newer ex. I didn't see any mention of odd bolts in the Haynes manual for my truck (93xlt).

 

[RobbieJ]

Hey Kris, My t-case is making some klunking noises too what type of noises and when does yours make them? Some times it feels like mine slips out of reverse when its in a hard pull. It just starts poppong and then sometimes when it shifts into low it klunks. thanks Robbie

 

[JDraper]

Originally posted by chrisb
Thanks for the reply...

Did you change a BW 13-54 (first generatio explorer)? I noticed you had a newer ex. I didn't see any mention of odd bolts in the Haynes manual for my truck (93xlt).

I had a '92 sport up until it got totalled in January. I took the Xfer case out of it. The manual doesn't say anything about the bolts being different, but the ones that hold the drive shafts to the xfer case are 12 point bolts, and can be a pain to get out without the right wrenches.

 

[chrisb]

Thanks for the info on the bolts...

As for the type of noise the t-case is making, it is a constant clicking whenever I'm moving faster than 5 mph. The truck still works fine... 4 high and low work (although my hubs are crap... replacing with manuals)

I found a used t-case for $250can (~$170us)... no motor, but I just cleaned mine and it works great. I'm going to install it this weekend... I post about how it went on here.

Later,
Chris B

 

[RFR2212]

Stubborn Bolts....

Like JDraper was saying...The rear drive shaft can be stubborn. MAKE sure you soak em with some sorta penetrating fluid, and I used a 12mm 12pt socket, untill it broke. Then I got away with my 1/2in close ended wrench... But they sure are stubborn! Oh yea, I've pulled my t-case and it's really not that hard.
Pete

 

[RobbieJ]

I'd be willing to bet that the chain is loose. I'm pretty sure thats whats wrong with mine. This weekend I'm going to be rebuilding it. Thanks for the info Robbie J