Transfer Case removal & replacement

[smeltjr]

After hearing a loud grinding noise after the car would get above 5 MPH, my 1996 explorer was recently diagnosed with a bad transfer case, insides shredded.

I took it into the Ford dealership for the diagnosis. They claim to have taken it apart to do a complete inspection of the unit. They charged 4 1/2 hours of labor, $409, to do this. They wanted $2,300 to install a new one. Well, seeing how the truck is worth about that much, I wasn't going to pay them to put in a new one. After reading posts on the forum, decided I would try to do this myself. I picked up the truck from the dealer last night and was able to make it home, but this morning, the tranfer case was leaking fluid all over the floor; it never leaked before. The fluid is coffee-like in color. My first question is, wouldn't the dealership have to drain the fluid to inspect the interior? That being so, wouldn't the new fluid be clean? Did they even inspect the unit? Did I do more damage by driving 5 more miles on it?

Secondly, I have called around to local U-pull it salvage yards, which will charge around $100 for used transfer case, if they have one on the lot. After I pull the unit at the lot, is there a way to check to see if it is good?

Finally, I have taken the bolts out of the front axle input yoke, but cannot seem to get the driveshaft and boot out. The Chiltons manual talks about a clamp, if equipped, holds the driveshaft boot to the transfer case. I don't see a clamp, but if there was one, what would it look like?

Thanks for any help anyone of you can give.

 

[IZwack]

hi there -

yes if the dealer put in new fluid - that fluid should be a cherry red color (ATF) - not cofee like. I don't have much experience with tranny internals so i don't know whether or not you did more damage to it by driving it the 5 miles back home.

if you're going to a salvage lot and pull the t-case out of an X yourself, i think a decent way to tell whether or not this new t-case will last is by checking out how many miles is on the odometer.

I don't have much to say about your last question because i have a CV type front shaft which is held in by like 6 or so bolts to this cup-looking reciever of the t-case.

good luck!

 

[F14CRAZY]

Without opening it, I guess feeling for backlash between the input and output shafts would be only way to determine way other than checking how many miles the donor truck had. Decent salvage yards have not DOA warranties.