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Old 11-11-2011
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Help with transfer case..

Hey guys.

To add to my recent slew of posts, I might as well add this one.

02 FX4 twin stick 5-speed with about 88K.

So, my next move in my pursuit of a perfect drive train is/was to remove my transfer case, clean it up, replace the leaking gaskets, then install with all new hardware (and put anti-seize on the damn things this time).

Ok so I have a Chiltons guide and I'm at the point where it says "Remove the 5 bolts retaining the transfer case to the bell housing extension, then remove the transfer case from the transmission."

The 5 bolts are out (after 4 solid hours of labor), but the transfer case doesn't want to budge!

Do I need to remove the rear drive shaft flange (some of you call it a yoke) to get the xfer case off?

What am I missing????


I also have another question so I thought I'd combine them into one thread.

If anyone here has ever replaced their front drive shaft, then they know a brand new one is a pain in the *** to put in. Well, I have a new one in but where the CV joint mates to the xfer case was bone dry when I took it out. After installing the new one, I've noticed grease EVERYWHERE under my tranny! It looks like all that grease came out of the new CV joint, but the boot isn't torn. Anyone ever experience this?

Thanks in advance.
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Old 11-11-2011
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sounds like the t-case is just stuck on the drive splines...try wiggling it or getting in there with a pry bar


you do have the shifter out dont you?
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Old 11-11-2011
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the OEM gasket on the tcase can be a PITA to get off, but it will come off.
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Old 11-11-2011
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Just went through this... keep wiggling and pulling.
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Old 11-12-2011
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Whew! Ok thanks guys! I may have a few hours today to try this. If not, I'll be under there on Monday.
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Old 11-12-2011
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its too bad your like a 2.5 hr drive from me or id come and help you out
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Old 11-12-2011
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Quote:
Originally Posted by djfllmn View Post
its too bad your like a 2.5 hr drive from me or id come and help you out
Not a big deal but I appreciate the thought.

Haha!! Your in York? I bought my 76 Trans Am from there! Oh what a drive that was with a U-haul truck and trailer.... I had never driven anything in tow until that day.
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Old 11-12-2011
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Originally Posted by Decaff2007 View Post
Not a big deal but I appreciate the thought.

Haha!! Your in York? I bought my 76 Trans Am from there! Oh what a drive that was with a U-haul truck and trailer.... I had never driven anything in tow until that day.
yep im down here in good ol york
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  #9  
Old 11-13-2011
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LOL I got it off!

It was just THAT corroded and stuck on there.

I ended up taking a large screw driver and prying around all the edges until the seal finally cracked. Then I hammered the screw driver straight up from the bottom of the transfer case.

Man... CORROSION!! I went and bought some course discs and and arbor for a drill and this combination should make short work of all the corrosion.

So, I'm also going to clean up the rest of the t-case and replace the leaking gasket (which is why it came off in the first place.

Then, some brand new ATF, tap out the threads (none are stripped but I'd feel safer doing this), brand new hardware, and I don't know whose genius idea it was to use thread locker on the transmission to t-case bolts, but I'm half tempted to use anti-seize instead.

Now, I just have to actually FIND new hardware and gaskets...
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Old 11-13-2011
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Use blue threadlocker, no worries of the bolts getting loose. Fastenall should have the hardware...or Ford
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Old 11-14-2011
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Originally Posted by rolsmojave3 View Post
Use blue threadlocker, no worries of the bolts getting loose. Fastenall should have the hardware...or Ford

Yeah I'm going to have to go to Ford for this one. Every time I go to the Fastenall here, the guy looks at me and shakes his head while saying "We don't have it and can't order it".

It's like he doesn't even make an attempt to look for what I need. Lazy B****

The guys at the Ford dealer are even worse. The one guy swears I told him I pulled the perfectly running 4.0 out of my 02 FX4 and swapped it for a lesser, higher mileage motor. Then he tells me that there's 7 different driveshafts for my truck and he can't order hardware for it w/out seeing the title. The TITLE? Wouldn't the registration do (I'm assuming he needs the VIN)? He's like no, I need the title.

I thought yeah screw you. Go eat the rest of your donut while I go to the j/y to get the 4 bolts I need.....

I'm going to try my luck with a different (albeit further away) dealer today. I've heard they actually give a damn about their customers.

Anyway, I'll keep you guys posted on how things go.
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