Two ways to go about getting the transfer case out. You can just unbolt the transfer case from the transmission slide it back a bit and then drop it out of the truck. I prefer, now after a couple time doing it this way, to pull them as one unit. Transfer case and transmission attached. Less mess, less chance of damage to the equipment and your body.

To pull the single unit out you have to drop the torsion bar cross member.

First I paint the torsion bar key bolts so that I can put them back to the same spot. Hard to see here. Also not you need to have the weight off the front suspension.


Run the bolt out. Attach this nice tool, crank it in a bit and release a bit of pressure and pull the thingamjig out Then drive the torsion bars forward and drop the keys.




Remove the 2 bolts on each end of the cross member and pull it out.


Don't know if its important but I keep all the stuff together and marked.

 

Next we get the transmission cross member out so that you can drop the trans a bit and get to everything else.

Support the transmission/transfer case with a jack. 4 bolts at each end of the cross member, and 2 nuts in the center that bolts up the transmission mount.




Once the member is out, drop the trans a little and go at the connections.
Rearward of the trans. 2 sensors on each side of the output shaft. Also undo the wire loom keepers.




Next to the other end of the transfer case. Disconnect the main plug for the transfer case and one other sensor. I also just remove the 2 nuts that hold the support bracket for everything running rearward.


Next remove the shield on the passenger side of transmission. Undo the main plug for the transmission and undo the transmission cooler lines. I just use pics to remove the clips on the transmission line locks. Kind of a PITA first couple times you do it.

 

10 more bolts.

The mother%$#*(*&^


Long extensions, and swivels are your friend.


Left the two final bottom bolts on and got the jack lined up and supporting it.


She's down. Now how the hell do I get the truck another foot into the air to get it out from under the truck?
The new jack is great but causes other problems.

 

I ended up sliding my trans off the jack and onto a sheet of tin. I removed one front wheel and was able to fit the bellhousing out from behind the front wheel where the chassis rails kick up and slide it on the tin. A piece of old carpet would work just as well as a slide.

 

Howard that is the smart way now doubt about it and the way I've done it in the past.

I've had a few drinks today and decided to do something stupid instead. Scared the **** out of me.

I anticipated some issues with height. A buddy dropped off a couple 6X6's for me a few days ago. Didn't quite know how I was going to use them. Thought under the wheels as I jacked it up but forgot about no suspension.


Kept jackstands under the frame as I went up with it. Had to pull the one out on this side when I got it high enough to roll it out.




It worked but I'll plan something different if there is a next time. I need a couple more drinks! Phew!

 

Well done!
Gotta admit...the timber on the jack looks scarily familiar
I built a set of heavy stands and basically did the same as you.
Have you thought about what you're going to do for cooler lines on the 80E yet?

 

I've bought a set of factory cooler lines for a 2500HD.

 

Threw in the new cross member to make sure it at least fits into the frame rails.


Split the transfer case from the transmission.


This trans is a low mile stock 65E with shift kit and servo's. Maybe 6 passes down the track 2 with nitrous. I put maybe 2000 miles on it in the 8ish months its been in the truck. Still performed perfectly when I pulled it into the garage. Some signs of clutch material.


The collection that will go up for sale in the future to re-coupe some more mod money.


Tomorrow I'll tear into the transfer case.

 

Is it just me, or is there a tad bit of a twist in those output splines?

 

I had to go look at the transmission. Think its just the photo..