zlathim

Hey guys, I just got a new to me 1993 SR5 V^ 4x4. The transfer case is leaking and it is coming from the mating surface between the rear case and the rest of the TC. I can see someone has had it apart sometime in the past because there is orange sealant between the rear case and the front part. It looks like this:



I was hoping that I could just remove the rear case from the rst of the unit in the vehicle. Is this possible? I have already removed the rear DL and all of the bolts around the edges of the rear case:



Can I just pull that rear case off now? Is there something I'm missing? I cant get it to budge, but I haven't tried too hard just in case I am missing something. Anyone that can help would certainly be appreciated!!

neoworm0

http://personal.utulsa.edu/~nathan-b...16disassem.pdf

neoworm0

I would pull the extension housing off and remove the speedo drive gear and retention ball. The rear half should seperate from the front then. If you read the Diassambly instructions they say to remove a bunch of other things first but I cant' visualize how they would connect to the rear cover in any way. I've never had the VF1A apart though. Only the RF1A's. Try hitting it with a big dead blow hammer. It may just be stuck on pretty well.

zlathim

Thanks a bunch for the info! I'm working on it now, so I'll let you know how it goes, thanks aagain for the info.

neoworm0

Actually looking at it again it again it looks like the shift rails come out with the rear cover. You may have to at least remove the stick.

neoworm0

Looks like the front output flange has to come off too. Not as simple as you were hoping I think.

zlathim

Neoworm0, I finally succeeded in getting it all apart and put back together. It was necessart to pull the extension housing off first in order to get at the speedo gear, ball and bearing retainer. The rear case did come off leaving the shift rails intact in the front portion of the case. I did not have to take the front flange off, in fact the picture in my first post showed the rear case ready to remove, I just wasn't persuading the halves apart hard enough. I guess I was afraid of breaking something, but eventually I just let it rip and the rear cover came right off. In this picture you can see the shift rails at the top.



I did have to remove the rear output shaft bearing retainer in order for the bearing to pass through the rear cover and remain with the chain and sproket assembly. Heres the rear cover ready to be cleaned, you can see the shift rail bosses at the top:



It took some finesse to get the cover back on, especially with the two shift rails entering the bosses. I finally got it all assembled and the detent springs and balls installed correctly and everything put back together and full of oil.



Now I'm dead beat. It is almost 1 am and I have decided to wait to test drive it until tomorrow morning. Thanks a bunch for the advice and the link to the manual. You rock!

neoworm0

Glad it worked out for you.

MudHippy

Nice write-up there newby!

Seriously though dude, you kicked that ones ass. Way to contribute with the pics of it all too. Good job!

zlathim

Thanks MudHippy- It was a fun project and the help I got here was awesome. Thanks again for the warm welcome.

leebee

hmmm... i was under the impression that you had to r&r the tranny to get the tcase off. ill have to take a good look through the manual again. my case is cracked from some severe hits on the canadian shield, jb weld has held pretty well until ' i did it again '.

lee

zlathim

Well, I only removed the rear case off the tcase, not the whole tcase. I am pretty sure that it is possible to pull just the tcase leaving the trans in the vehicle, but you have to support the tranny/rear of the engine somehow because the rear mount is on the tcase. Place a jack and a block of wood under the trans in front of the crossmember and you should be in good shape.

JB weld is the shiznit though, I used it on a side case of an old yz400 dirtbike because I couldn't find a replacement after cracking it in a crash. I rode it for years and it never leaked a drop of oil past the JB weld. If it is holding ok, I would just leave it alone!!

neoworm0

HEy LeeBee. I've got the original V6 tcase out of my truck from when I did the duals. It's mint and it's yours for free if you want to pay to get it too you. Seems I can't give the damn thing away here. It's going in the dump soon, otherwise.

LS1Steve

Whoa i have dibs on that if he doesn't take it!!!!!!!!!!!!!!! I just replaced everything with a JDM unit, and can't dig up enough info on how to get the electronics right (4wd is actuated by a motor on the tcase, blegh!)

neoworm0

Well my email is tradman@telus.net. First come first served. It's been sitting in my garge for a year and half now and I just can't bring myself to chuck it. Seems no one here has any need for it. Including me.

Like I said. Nice and tight and very low miles.

leebee

hey steve!

go ahead and make the deal, i have a complete driveline in my garage from an 89 v6 so im good to go for a spare tcase.

neo, thanks very much for the offer, appreciate the thought.

zlathim, ill be using your tips this winter when i try pulling the cover to repair or replace it. thanks guys!

lee