I have my drive line out. Sent the TC out for a fix. I have always separated the transfer case from the transmission for 3 reasons. I do this by myself, on the garage floor, don't have a transmission jack and it's too long to clear the torsion bar and drop straight down... ooops 4 reasons. I separate the transfer case, muscle it down and put a 2X6 under the trans pan and jack it straight down after its loose.

Anyway I always wind up with a pesky leak between the t-case and tranny and wind up pulling it back apart redoing the gasket. Not a bad leak just a drop or two kind of thing and keeps the area wet with tranny fluid. This last time I never did get it stopped after a couple tries.

So I've cleaned up the mating surfaces real well. Pulled out the studs and sealed them.





I want mate them up on the floor along with some sealer to make sure I get the gasket right.

Now getting this monster back in the truck is gonna be a PITA. Think I'll call in some favors and get some help this time.

 

good luck.

 

Your problem is you are serperating the t-case and trans at the WRONG place

The adapter needs to go with the t-case and it will go much easier and there is a little thin rubber ring gasket that seals.

 

Tried that the first time I pulled the tranny. There wasn't enough room to pull the x-fer case back and off, clearing the output shaft.

 

Thats how I have done mine and two other 4wd trucks and an SSS, it WILL come off you just got work with it. Pull it all the way to the back dont support the trans at all so it dropps down, tilt the output of the tcase over to the pass side and wiggle like hell and it will drop down. There is a heat shield there that on my truck I bent up with a hammer to make it easier but I didnt do that on the other trucks and still managed to get it out and no leaks after I put it back in. Take my advice for what its worth but it does work.

 

I always pull mine at the adapter and case never had a leak. Use the right gasket and a little black rtv. I am a mech. by trade and have done mine now twice.

 

Yeah, I didn't spend a whole lot of time trying to make it work. If I have to pull it again in the future I may it try it again.

 

I've never used rtv and always GM gasket. I think fluid is actually seeping into the threads of the studs and making its way out the front. Anyway I am going to use rtv this time to seal entire surface an particularly around the studs. It will be much easier to do on the floor and mate them there rather than trying to get it right up under the truck.

 

when you putting it back in. ill come by and help if your pretty close to stanford ky. just shoot me a pm and if im in town ill help you out no problem.

 

I'm sure you know this but harbor fright sells a trans jack that is pretty cheap. I have never pulled the t-case back off the 4l80e. Of course I do get to pull the f-ing torsion bar crossmember.....