How do you remove the top bolt where the transfer case mounts to the tranny? I have alot of play where the front driveshaft goes into the transfer case, so I either need to rebuild that part, or put in a different transfer case. I was looking at how to replace it, but can't figure out how to get at that top bolt, otherwise would I be better off fixing the existing transfer case? I can buy a used case with 85k on it for $100.00, didn't think that was too bad.

 

When purchasing a used transfer case, does it matter if it is for a 4spd or a 5spd, or are they the same?

 

As long as it's the same as the one you're taking out (can't use a forward shift for a topshift) and they're both 4cyl cases it'll work.

 

So could I use a case that is newer than 83? Everything I have found in my year range usually has 190,000+ miles on it, would like to see something with around 100k on it. What years will work?

 

only the L-series t-cases will work for you.

 

Sorry for being stupid, but what is a "L" series transfer case. I am a paint/body man and when it comes to mechanical compatability and interchange I am clueless. Thanks

 

your transmission is an "L" series. Thats the trans identification. If you look at the info plate under the hood, there is a A/TM thats axle code/transmission code. Should be an L52 methinks?

 

The first time I pulled one I had to loosen the engine mounts to get enough angle and used a long extension on an air ratchet. Second one I pulled the whole engine. It was much easier.

 

Thanks for the reply. Loosening the engine mount bolts is kinda what I was thinking too. Didn't really want to pull the engine, would have to buy a cherry picker then. Did you have to use a transmission jack to support the transfer case and tranny, or is it fairly light where two people could fanagle it out? I was thinking I would use just my floor jack with maybe a block or something.

 

those cases full of fliud weigh about 78 pounds. And to more easliy I.D. your case look carefully at it, is the t-case shifter in the trans housing(forward shift) or in the t-case itself(top shift). And as far as the price goes, Ican get them at my local U-pull for 53 dollars. Good Luck

 

There is no need to loosen the engine mounts. I have had mine out twice and neither time did I have to do that. Use a transmission jack on the tranny (or substitute a floor jack if it will reach), remove the crossmember, lower the jack, there is enough play in the mounts to allow the engine to lean back due to the weight of the tranny and t-case. There is also no need to remove the tranny if you are replacing or removing the t-case AFAIK. Just remove the d-shafts, unbolt the t-case from the tranny, unbolt the crossmember as I said earlier, then pull the t-case out of the tranny. If it doesn't want to separate, a dead blow hammer or rubber mallet can usually persuade it to come apart. Fluid will probably leak out the back of your tranny, so have a drain pan ready. I removed one and installed another with 2 people (drained to lower the weight a bit) and although it was a minor hassle, it wasn't too bad.
You can open up the case and replace the worn out parts, it is possible. I had mine apart to install 4.7's and Marlin gives AWESOME instructions. Marlin has a t-case rebuild kit here:

http://www.marlincrawler.com/htm/tra...e/tcase_ac.htm