Unfortunately, I've got an autotrac transfer case that's leaking from a hairline crack in the rear half of the case housing. It's coming out of the truck this weekend, and the new rear housing should be here Thursday from Parts Zone. Additionally, I've got the gasket that's between the T-case and trans adapter, and the rear output shaft seal on order.

I'm looking to drop the case and replace the rear housing myself, and I know there are a few of you out there that have had the case apart for your 80E swaps . . . . Any advise on what to look out for, other parts I may need, or special tools?

I've already found that snap ring pliers are recommended to change out the input gear for the 80 swap--will I have to have them to replace the back case half?

Thanks,
Kipp

 

just a fyi... the cases are weldable. mine had some spots ground through from being wrecked and we were able to tig weld it with magnesium filler rod.

 

Yes you will need the pliers.

I have got a write-up on this, but I cannot figure-out how to post it.
Give me your e-mail and I'll send it to you.


And if some-one can tell me how to save picture from Microsoft word, so I can host them with the write-up, I will post it.
Or you can just hound z7199 to send me the pic.s

 

Wilde--I sent you a PM with my email address. Below is how I'd suggest you save the pics out of Word (or I'll save them out at work tomorrow or Wed. and email them back to you, if you'd prefer). Thanks . . .

There are several ways to save a picture back out of a Word document. Right-click on the picture, copy it. Then open something like Photoshop, or Microsoft Ofice Picture manager. In Picture manager, select paste off of the edit menu. This will let you save the image as a png file. You can then use document imaging, paint, etc. to open the png file and save it in a more usable format, like jpg. In Photoshop, the process would be the same, except you'd choose New from the file menu, then paste in the image from Word. And, Photoshop will let you save directly to almost any format.

And back on topic, the transfer case is off of the truck now. Removal was a breeze, especially with a set of automotive picks to release the clips on the electrical plug-ins.

 

Sweet. I'll be posting the write-up shortly.
You should have mail!

 

Update for those interested.

Case is out of the truck, and apart. Problem is that the tabs on the oil pump have worn through the housing of the transfer case! All caused by a broken oil pump retaining spring/wear protector . . . I have taken some photos and may post a few of them, although Wilde Racing's how to thread is sufficient.

 

ouch, Are you going to try and weld it or replace the rear section of the case?

 

Update . . .

I replaced the rear section of the transfer case last night! I ordered a new one (# 12474949) from Parts Zone, and it came with the tailshaft bushing, rear roller bearing for the front output, and the oil pump retainer/wear protector already in place. All I had to do was replace the tailshaft seal and swap the snap ring over to the new case half. Then re-assemble everything.

The truck is running again! I took photos and may try to post a few when I get the chance. Thanks again Wilde, for the write-up!

Kipp