Engine/Transmission (1998.5 - 2002) Transfer case

[MSears]

I need to replace the input and output seals on the transfer case on my 2000 Diesel. How heavy is the transfer case I don't want to do it myself if I can't handle it.

 

[DIESELWRKS]

a transmission jack is best if you can get one. but yes 2 people are safer. I dont think a shop would be that bad. if you can find a place that would put in your parts you bring. Home has great seals and may have some . DIY info on those seals.

 

[Gene Heck]

transfer weight

If you have a 241 it weighs 80 lbs. A 241HD weighs 100 lbs. They are not that heavy. I have never used a jack to get one of those out. After you remove all the linkage, shafts etc. and you remove the six nuts holding it to the transmission case it will just hang there by itself until you can get under it to slide it back and down. I don't have a lift, I work off a creeper. If it has never been out before and you live in the rust belt it is not uncommon to have a mounting hole or two on the transmission case corrode around the studs on the transfer case and you will have to use a lot of patience and penetrating oil to get them to separate without breaking a mounting "ear" on the transmission.



Gene

 

[MSears]

Thanks

Thanks, that is the information I was looking for. 80 to 100 lbs I can handle much above that it goes to the shop.

 

[DIESELWRKS]

I know you can do it yourself but my truck is lifted and if you have the ability to use a lift and a jack. it does make it easier on your self. my body has missing parts from the Marines so now days I would use another hand or a jack. and like he said may be agood idea to soak the bolts a couple times really good prior to taking it apart.

 

[kscheffler]

I have to replace my nv5600 output seal it is leaking. Are you guys saying that I can remove the entire 241hd transfer case as a whole unit just unbolt it from the transmission. I had to replace the back half of the transfer case this winter it cracked and in order to remove the back half of the transfer case I had to remove a snap ring on the output shaft. I don't understand how you can slide the whole unit off the transmission with disassembling the transfer case body? Getting the snap ring off was not fun. Becareful when you reassemble and use the black silicon sealant when assembling the case make sure you get sealant around each bolt hole or it will leak; don't ask how I know this... . thanks kts

 

[Gene Heck]

I wouldn't advise you to use any sealer. Put a little never sieze or grease on the splines and also on the studs of the transfer case so they don't stick together. The front of the transfer case has a seal and the rear of the transmission has one also. They are separate from each other. If you look close there is a slight "notch" at the bottom that will drain any oil that gets in between the trans and transfer. If they are sealed together they can't breathe or vent pressure to the outside. The factory never used any gaskets or sealer since there isn't supposed to be any oil in there.



Kscheffler,



You're disassembly is the same as MSears. There isn't any hidden parts like snap rings connecting the two you have have to worry about. Once you disconnect the driveshafts and linkage, vacumn lines etc. from the case it will slide right off the rear of the transmission unless some corrosion has it stuck. Since you already have a leak in one of the cases your's will probably slide apart easily for you.



Gene

 

[Gene Heck]

Kscheffler,



I just reread your post and might have mistaken what you meant when you said to seal the case. I thought you meant to seal where the transmission and transfer case mate together. On rereading it it appears you were talking about reassembling the transfer case halves. My apologies for the misinterpretation.



Gene

 

[kscheffler]

No problem Gene I understood what you were saying. The extenstion cone and the back half of the transfer case do need sealant and that is what I was talking about. I guess you do not need to remove the snap ring on output of the transfer case as long as you are NOT removing the extension cone. So removing the tranfer case seems like an easiter project than replacing a crack transfer case housing. Watch that transfer case housing mine had a fine crack and was leaking oil. I was amazed how thin the transfer case housing is so keep an eye on the back half of those transfer case housings.

 

[JMcCoy]

I pulled mine of laying on my back. Not that heavy. If you can bench 80-100 lbs. you will be fine. In case your hand slip or you lose balance, make sure your chest is under the case, not your head. I did it with no problem and would do it again that way. Installation is a pain, if not impossible, by yourself. That said a transmission jack would be far safer. Good luck