Transfer Case & Trans glued together

[josephemd]

Putting in a new clutch in a 1994 Expl at 113,000 miles. Had to remove the manual transmission and transfer case as a unit as they would not separate; it's like the gasket has glued them together. Would rather put them back on the car one after another, making it easier to handle the weight and align the output shaft. They are very stuck. Any ideas on getting them apart without marring the mating surfaces?

 

[josephemd]

Got it

Never mind. I got them apart.

 

[2thumbs]

Hey there, I'm having the same issues with the transfer case and the transmission not separating. How did you end up getting them apart? I've taken out all 5 transfer case bolts, and when I attempt to slide the t/c rearward I can see a slight gap between it and the tranny, but that's about it.

Any help would be appreciated, thanks!

 

[Lacky01]

I think there should be six bolts...

 

[josephemd]

To get them apart I first used a stiff putty knife, to force a little space in the paper gasket. Then I took another putty knife that has a beveled edge, and is thick enough that it will not bend. I gently tapped it part way in at several places, trying to pull the transfer case off evenly. Do not get impatient or you will score the faces or break something. The worst part is getting the old gasket material off the transmission and transfer case faces. I tried a Permatex product that was almost useless. I used a plastic scraper as much as I could. I did not use any gasket sealer on the new gasket. When remounting, get that bottom bolt in place on the transmission before putting on the rear trans mount; the bolt is just long enough that you cannot get it in after the mount is on the cross member.