Well I messed up... transfer case toasted

[Thump]

Update on both accounts...
We met with the vet oncologist Wednesday morning. Our dog definitely has a metastatic cancer and it's in his liver, spleen, and kidneys. His pancreas isn't too happy at the moment.
We've decided to do palliative care for as long as his quality of life is ok. He doesn't act like he's in pain (still wants to play as normal and doesn't give us "that face"). Doc said to spoil him, so we are. No prognosis on time left, but I figure weeks to a couple months.

I picked up the transfer case from the dealer yesterday. That was fun getting the 150# 2' deep x 2.5' wide x 2.5' tall box into my TJ with the back seat partially tumbled and soft top on... with a fork truck.
It's now in the bed of the truck and I had AAA come flatbed the truck to the shop last night. I'll R&R it this weekend. Remove and replace or rest and relax... you decide At least there I have a lift, trans jack, and better tools B)
If I think about it, I'll write up the procedure. Seems really straight forward with two driveshafts, trans mount, one plug, one hose, and six bolts. I hear it's a pain to separate the trans and tcase, as well as clear the crossmember without dropping things.

 

[Thump]

Final post in here, if you have questions, feel free to ask.
Tcase has been replaced and the truck is back on the road. Took all of two hours of actual work. Due to my c-spine damage affecting how long I can hold my arms up, my lumbar spine damage making sitting for a few mandatory about every 30 mins and taking lunch in the middle, that time became about 5 hours LOL.
It's really straightforward, especially on a lift. The hardest part was the upper passenger case to trans bolt. There's no room for air tools or a real ratchet, even with the trans and engine tilted as far back as the engine mounts allow.
Pull driveshafts
Remove skid plate and rear crossmember
Support trans (block of wood and screw jack)
Unbolt three trans mount nuts from front crossmember and lift trans up
Remove front crossmember with the aid of a pry bar
Remove trans mount (4 bolts)
Disconnect shift motor and vent tube
Support case with trans jack
Remove six tcase to trans bolts and yank it out
Install is reverse of procedure
Using the trans jack for the rear driveshaft made it a one iduot job, especially install.
Thanks folks. Time to go play with the dog for a bit

 

[Lakatos]

Thanks for taking the time to bring this to the forum.

Any ideas for the cause of the leaking slip yoke?

 

[Thump]

There is a small cap that's barely more than a foil plug at the end of the slip yoke that barely sits in there. That's what was leaking.
I've seen all manner of fix attempts on the Internet with a hit or miss success rate. Seems the real fix is replacing the yoke.
I didn't replace mine, yet, as I didn't get it in time. I've ordered a new one from AAM and will replace it and the u-joints in the rear shaft when it arrives.
Another fix is to do a slip yoke eliminator. But that involves opening up the case to put the Ford output shaft in.

 

[Missouri Mule]

Thump I take it used blue goo for water pumps and oil which is ok. I suggest if that cap doesnt have to come off use 1a gasket stuff if it needs to flex use 2a gasket sealer ( it's Brown and it will resist all type of stuff. I used it on few leaking pool piping joints. I used the one that dries hard.)
Sorry about your best friend. Lost my cats several years ago.