T-Case removal?

jeepers · **Posted:** Wed Oct 19, 2005 10:15 am

has anyone taken there transfer case out? i need to do this to fix the seal on it. if anyone has any info on this please let me know thanks
Jeepres

DaveKJ02 · **Posted:** Wed Oct 19, 2005 10:59 am

I just looked at the instructions in the service manual and personally, I wouldnt do that job myself. I do a lot of work myself, but besides changing the fluids in a transmission and transfer case-fixing them is out of my league. Heads up-there are a few specialized tools to aid seating the seals referenced in there too.

chefdab · **Posted:** Wed Oct 19, 2005 11:13 am

Hey while you've got it out, why not just replace it with a new one with a 4:1 low range?

jeepers · **Posted:** Wed Oct 19, 2005 2:13 pm

well what is going on is the seal thats on the back side of the t-case is leaking

. not the one were the drive shaft comes in but the one where the case comes apart. i have tightened the bolts on it and it didn't seam to mater. i called the dealer and asked about the seal and they said that there isn't a paper gasket but its gasket maker.

i guess i really worded my question wrong. what i am wondering is would it be easier and/or possible to just remove the rear plat of the t-case to reseal it or take it out?

if i had the $$$$ i would replace it with a better one :twisted:

but no money means i am going to keep it for now. what type of special tool is needed? can it be rented?

USPLibby · **Joined:** Thu Jul 28, 2005 12:29 am **Posts:** 377

I've worked on T-cases before but on Land Cruisers and those are heavy as hell. They come out pretty easy but it takes two people to safely remove/handle if you are working in your driveway.

If you have access to a professional lift and one of those adjustable transmission jacks, it will be a lot easier.

krazz1e · **Posted:** Wed Oct 19, 2005 6:11 pm

A leak? ahh don't do all that work for a leak, just keep adding fluid and you'll be fine!

It's an automatic flush :wink:

JediJeeper · **Posted:** Wed Oct 19, 2005 7:14 pm

Chances are that you have the 242J transfer case. It is quite easy to remove. You will need to remove the cross member (remember to place a jack under the transmission first) and the drive shafts. Then remove the four wheel drive indicator light harness and the shifter linkage. Optional: drain the fluid from the T-case.

There are around 6 bolts holding the T-case to the transmission adapter, pull them out. When you do, a bunch of ATF with come from in between the trans and T-case so watch yourself. The T-case will try to swing the front output side down when you get the last bolt out, let it rotate down slowly. If it doesn't do it on its own.. pry it away from the transmission adapter a little bit. Watch your head so you don't get smacked by it as it rotates down. Let it drain for a while there.

The 242 is actually pretty light, I think around 90lbs, I usually just slide under on a creeper at this point and pull it off the trans output shaft (about 4 1/2 inches straight towards the back of the vehicle) by hand and roll out with it. If you are uncomfortable with that, get a friend to help you pull it out.

Make sure all the RTV/gasket surfaces are really really clean when going back together and that they have a new gasket or RTV on them.

-Adam

jeepers · **Posted:** Thu Oct 20, 2005 7:19 am

you guys realy have helped me out. i see they have published a hanes manuel for the kj now i am getting one this week. with your help and hanes it will be much easier.
thanks again
Jeepers

T-Case removal?

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