Engine/Transmission (1998.5 - 2002) Transfer case tail removal

[TSRAM]

I am trying to get into the transfer case to get to the supposed broken snap ring, but the tail housing doesn't want to come off. Am I missing something?? I've got the driveshaft out the four bolts out of the tail, but it feels like it still has something retaining it on the inside. Tried slight prying with a screwdriver, but don't want to break something else.

Anyone done this on here right now? I would like to get this done ASAP.

OK reading some old postas that keep refering to the access to the snap ring to remove the housing. Is this access the large retangular window on the side of the tailhousing?

 

[JSykes]

You are in for a treat.....

TSRAM,



I did the transfer rear extension housing removal on my '99 2500 couple of months ago. I am still cussing the Dodge engineers to this day for that experience. But since I know the right procedure, I feel I could get it knocked out in half a day.



This is the way it went on my 241HD transfer case:



1. Remove drive shaft and set aside

2. Drain transfer case fluid and reinstalled plug finger tight

3. Using brake parts cleaner, sprayed down the top of the rear housing extension.

4. Wipe everything down to remove as much dirt from the rear of the transfer case itself and the top of the rear extension.

5. Remove the (4) bolts that attach the rear extension to the back of the xfer case.

6. Position yourself so you can look at the top of the rear extension. You will see a black rubber cover that is oval shaped (about 1"-2" in length) on the very top

7. Pry the rubber cover out with a small screwdriver. Do not puncture this cover with the screwdriver.

8. Once this is out, feel inside the opening for a snap ring.

9. Position the snap ring ends in the middle of the extension housing opening. The snap ring does not have any holes in the ends for snap ring pliers.

10. Due to the tight clearance, I cut most of the handles of my snap ring pliers. Of course I had a cheap set of snap ring pliers. Would not cut the ends off of a Snap On set.

11. Using the newly shortened pliers, I wedged them between the ends of the snap ring and held it open as far as I could. You will need to hold the pliers with one hand and pull on the rear extension housing with the other hand. The snap ring fits in a groove in the rear extension housing and snaps over a bearing on the rear output shaft. It will take several tries with the snap ring pliers to free the extension housing.



For getting the snap ring back into the proper place during the reinstall, I found it was the best to rig my own tool. I had some 1/4" thick steel that I cut to about a 1" wide strip. I cut two grooves in the sides of this 1" strip. I wedged the snap ring open and slid this piece of steel in between the ends of the snap ring. The snap ring seated into the grooves in the side of the strip. I then took the rear extension, with the snap ring wedged open and seated the rear extension back in place on the vehicle against the transfer case. Once I felt that the rear extension was in the right place, I removed the steel wedge. The snap ring should snap right into place. Pull on the rear extension to make sure it seated properly.



PM me if you need any additional information. I can give you my cell # and I can talk you through it.



Good luck with it.



Jay

 

[willyslover]

same for DLD ???

he has the std duty one in his auto rig I believe.

 

[DJW]

Of JSykes, although I only own 2wheel drives and don't expect to ever have that type of problem, people like him are the Salt of the Earth, sadly, the World is too short of that kind of person. Scrum Down.

 

[mongoose]

How do you tell if the snap ring is broken and what are the symptoms a person should be looking for? Thanks!