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Unread 12-14-2011, 11:08 AM   #1
nightridder
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Removing the transfer case with some problems

hi im new to the form and im new to the jeep world but i had a struck of bad luck the other day. i was just taking off from four way stop and i hear a loud crack then grinding. i role to the side of the road and see trany fluid just flowing out from my transfer case. i though i had just cracked the extension housing because that all could see at the moment. so i got a toe home and took the rear drive shaft off then took the housing off and found out that it was also the outgoing shaft that broke and i mean it really broke. i have pictures of anyone wants to see and it helps me out.

my problem right now is that i cant removed the skid plate because the bolts are welded in to place. why that was done i have no idea. so my option now seems to be that i have to just take it out with out removing it......anyone got some advice before i start going at it?

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Unread 12-14-2011, 11:11 AM   #2
scubamc
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It is going to be almost impossible to remove the tcase without dropping the skid. Cut off the bolt heads then drill and retap.
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Unread 12-14-2011, 12:35 PM   #3
jsawduste
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It is going to be almost impossible to remove the tcase without dropping the skid. Cut off the bolt heads then drill and retap.
OR

Take it out from the top by removing the tub.

Cutting a hole ion the floor comes to mind also....................
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Unread 12-14-2011, 12:37 PM   #4
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what are you referring to when you say remove the top? is that something that you can do and then undo easily
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Unread 12-14-2011, 12:41 PM   #5
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Unread 12-14-2011, 12:42 PM   #6
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Unread 12-14-2011, 12:45 PM   #7
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You can't remove the t-case with the skid in place.

1. cut the skid off
2. chop big strategic holes in your tub to access the t-case bolts.
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Unread 12-14-2011, 12:50 PM   #8
Ripper3494
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ive done that, you need to drop the skid plate, ive done it with it up once and it was probably the worst experience ive ever had with my jeep. my skid was welded as well... what i did is drilled out the original bolt holes and welded new studs sticking straight down for the skid to bolt onto
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Unread 12-14-2011, 12:54 PM   #9
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this seems to be getting more and more complicated. what would you all estimate is going to cost to fix this?
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Unread 12-14-2011, 12:57 PM   #10
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A used t-case $70 bucks.
cutting the skid plate off = the cost of cut off wheels
fabbing up new skid plate mounts = 6 bolts and welding

Figuring out why it broke where it did is just as important as the fix. How much suspension lift do you have?
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Unread 12-14-2011, 12:58 PM   #11
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can you post picture of how the skid is welded to the bolts?
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Unread 12-14-2011, 01:01 PM   #12
nightridder
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i dont have a lift on it. its all stock. and my bad but the bolts aren't welded it was the spacers that i was looking at and is welded. it has bolt with alen wrench heads and ive tried my hardest to get them to loosen with no success
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Unread 12-14-2011, 01:13 PM   #13
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which would be better. to just get a used to new tcase or to replace the outgoing shaft
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Unread 12-14-2011, 01:15 PM   #14
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i dont have a lift on it. its all stock. and my bad but the bolts aren't welded it was the spacers that i was looking at and is welded. it has bolt with alen wrench heads and ive tried my hardest to get them to loosen with no success

Something is strange here.

If it is all stock, it should not have any spacers. spacers typically come with lift kits to help with the drive line angles.

The are probably rusted in place. A few things...

1. spray them with PB blaster and let them sit.

2. if you have a torch you can heat the bolts up then try to remove them

3. it will take a lot of elbow grease to get them out.... think in terms of a 2-3 foot breaker bar.

4. don't be surprised if you break a few or they spin in place, we can guide you through fixing that

5. SUPPORT THE TRANNY WITH A JACK STAND BEFORE TRYING TO DROP THE SKID. The skid holds the t-case, tranny, and engine where it all is. you need to support the tranny just in front of the skid with a jack stand. I even recommend jacking the tranny up an inch, then putting a jack stand in. this takes any weight off the skid plate. you do not have much room to work with on the tranny, figure it out.

6. unbolt the 3 nuts sticking down through the skid plate first. before doing anything else

7. read all of these numbers before starting
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Unread 12-14-2011, 01:17 PM   #15
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which would be better. to just get a used to new tcase or to replace the outgoing shaft
in my opinion.... a used t-case would be easiest, quickest and least technical.
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