Transfer Kit Rebuild Instructions

[BigDave]

I've been told that my transfer case is starting to go bad at 130,000 miles. It makes a kind of whine and rub noise when moving. If I put the car in neutral there is no noise when revving the engine and it drives perfectly, no gear slippage. Soooo.....

I am going to get a used one off ebay and probably a rebuild kit for it too to make sure the internals are all good. My questions are these...

How hard is it to remove the transfer case from the truck myself?
How hard is it to rebuild the transfer case myself?
Are there instructions with pictures (or without I guess) on how to rebuild the transfer case?
What, if any, special tools will I need to be able to do this?

I am mechanically inclined and don't mind doing the swap and rebuild myself and have most of your basic hand tools.

Any help with these questions at all would be great.

BigDave

 

[Nick26]

well I can only speak for removing it, which is pretty simple and straight forward: unbolt driveshafts, unbolt it from tranny and slide it off the output shaft.

 

[Scott B.]

BigDave,

Removing/installing the case is straightforward and easy, though an extra set of hands helps. Rebuilding the case is easy, again extra hands may help.

We did mine in a day, so if you have the time, save your money and don't buy a case from the junkyard.

The instructions I used are in the factory service manual. I replaced 3 shaft bearings, seals, oil pickup, oil pump and chain. Doing it again, I would not replace the oil pump or the chain. Mine were in great shape. 245000 miles, but oil changes every 15K kept the internals clean.

Specialty tools - air impact and 30mm (I think) socket for yoke nuts, press and bearing splitter, a puller for a small bearing. I don't have the puller, we ended up using a dremel and chisel to split the bearing race. I need to get the correct puller.