Transfercase Install

Ok, so I just finished my transfercase overall. An idler gear, bearing, and arm were shot, along with some of the linkage. I also replaced the plastic plugs with metal ones while I had it out.

Anyway, I had a couple of buddies come over and help me bolt it up, or attempt to. I have one bolt, the bottom one started, however I CANNOT get any of the other bolts to line up-I'm off like a millimeter or two. I've tried everything from lightly jacking up the t-case on one side to get it to rotate, to trying to wiggle it and push it forward (like 15 times), to lightly hammering it with a BFH and a wood block, and several others but I'm out of ideas.

My problem is that the t-case is still separated like a 1/4 " from the T-18 on the top. I have all my gears-4H, 2H, N and 4L, with no binding, so that's not my problem. Am I missing something? This Jeep makes me feel like a mechanical rookie.

It looks like there is a hole on the front side of the T-18 flange to were I can maybe get a stud in there and just "pull" the t-case to the T-18, but idk. Can anyone help me out? As always, thanks in advance!!!

Oh btw, I finally tracked down that damn mount, it was an AMC mount, part # ANR 2921 (Made by Anchor Mounts). So if anyone is looking for one, or has one on their Jeep, write that down to save some frustration later...

 

Don't know for sure, but it sounds like something isn't right. I'm guessing you have a M-20 t-case. Something isn't lined up right. I've never done a M-20 t-case install, but I'm thinking the T18 output shaft must fit pretty snug into something on the t-case. I don't think I'd try to pull it in with a bolt. By the way, if you get a couple of bolts that are the same thread as the t-case bolts, but longer, you can cut the heads off and screw them in so you can slide the t-case over them and into position pretty much by yourself. They'll hold it there while you put in the other bolts. Then unscrew the studs and finish up the rest of the bolts. I do the same thing with the tranny when I re-mount it.

 

The bull gear on the tranny is not meshing with the input gear on the t-case. Try putting the t-case into 2 high and wiggling the output while trying to seat the t-case.

 

@Posimoto-Yep, I used two studs just for the bottom two holes as I have absolutely no room on top of the t-case to get a stud back out. This project has been such a pain. The PO bolted the t-case and the tranny and installed them at the same time, so there was only like a 7X3" hole to get the shifter through, so we couldn't keep it in 4L to install it like it's supposed to be. That's what the problem was I think.

@hudsonhawk-That's what I wanted to know, which gear to put the t-case in to get everything to mesh now that I have it on. Thanks! I'll give that a try.

 

Nope. I ended up just pulling it off again as I couldn't get it to mesh, and my gasket ripped through one of the studs and got chewed up. It's too cold and windy to work on it today, but tomorrow night after I get out of class, I'm getting in on one way or another.

I also ended up putting a stud in the top hole to help, but hopefully I can get it out and replace it with a bolt (no space). I also got a little bit longer studs too for the other two, so hopefully that will help out as well.

With school, bad weather, and projects due I haven't had any free time the last couple of days to work on it.

I'll keep you guys updated.

 

I get a bolt about inch or two longer,cut the head off then with hacksaw. I cut a groove across the top, you can use a screwdriver to unscrew it.

 

I am assuming this xfr case was on the same tranny before, not some new hookup you are trying to do???

A couple of things come to mind here, bearings with retaining rings, put in backward, and causing the bearing to not seat all the way.

Needle bearings in the input shaft/main shaft dropping out of place if the main shaft is allowed to move back when removing the xfr case.

I hope this helps.

 

Yes, just a rebuild of the t-case, not something new. The transfercase is rebuilt properly, for some reason I just couldn't get everything to line up, and limited space is definitely hindering me.

 

Well that's the last time I take my buddy's word for anything mechanical lol. The linkage bracket was catching on a lip on the side of my transmission on HIS side. I asked him three times to make sure nothing was catching, as that could be our problem, and he said there wasn't.

Long story short, different buddy, he saw it immediately, we adjusted it with those two square-headed bolts, and it slid on without ANY effort/pain. I told my other friend that he owed ME a 12-pack for being so mechanically declined...

Now I need to just bolt everything back up. Thanks guys!