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Head scratching about a transfer case swap...

1572 Views 9 Replies 7 Participants Last post by  boriskov
Hokay so...

I had the machinegun fire syndrome, and sourced a replacement TC, and went about fitting it. (for the record, you do NOT need an awkward plethora of tools to do this, regardless of what you read online).

Anyway, out with the old, took about an hour and a half, and pulled it out by hand by working on my back with the suspension at its highest setting.

and in with the new... or not.

It's not so heavy lifting the thing out of the car, but when you're trying to wrestle it up there at awkward angles it becomes twice as heavy.

So I got hold of a transmission trolley, and now have a bit of a dilemma...

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So yeah, you see my predicament...

I need to somehow raise the car about a foot to get the jack into the void...

Any suggestions? Consider that the exit to the garage is a steep slope, and can't really use the trolley jack as it's currently full of lumpy metal stuff.
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First time I did one, I had the same problem. Shoved the new TC under the car so it was in roughly the right place. Got the jack under there too and with two of us, one each side, a couple of assorted scissor jacks, blocks of wood, and a big lever, managed to lift the TC onto the jack so it could then be lifted into place. Like you, I ignored most of the instructions in RAVE and left the gearbox cable, the exhaust and the crossmember in place.
I am interested to see how you get on with this. I have just bought a NEW transfer box and it is ready to go in - by the way it weighs 70Kgs.

You could jack up the back and get car ramps under the back wheels. Might be a safety problem as there is no handbrake while you do it. Maybe chock the front wheels.
I had the same issue when myself and a mate swapped my transfer case over (was the same reason too - skipping chain)...

We ended up doing the same as GilbertD and wrestling the TC onto the jack whilst under the vehicle and then getting it up into place.

It is one of those jobs that would be far easier (but yet not impossible as a lot of us have still done it!) with a ramp and a tall transmission jack!
Mine was up on tall axle stands at one end and wheel ramps at the other, and it still wouldn't quite fit under whilst on the jack.

Let us know how you get on though, hope you can get another person to help get it in and into position. It's definitely easier on the way out with gravity helping!
or go buy a 2nd jack and raise the car. 2 jacks are always useful !!
Like you, I ignored most of the instructions in RAVE and left the gearbox cable, the exhaust and the crossmember in place.
Nah, I took off the stuff for the old box, but the guy who took this one off clearly didn't :p

Anyway, I only just checked this after trying to figure this out... I 2D'd a wooden box, and chucked the precarious jack on top... add wood... compress wood... add wood... rinse and repeat.

It's almost 5am in sydney, so I'm probably going to have to sleep sometime soon, but all this carpentry got me tired...

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Tomorrow is the big push, but I need more wood. Said the bishop.
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Eeek. That lifting process looks a bit on the precarious side to me.

Not been a fan of using hydraulic bottle jacks for that sort of step-up, add packing, step up again and so on since I dropped Bristol 603 off one which slid out from under trying a similar trick many years ago. Fortunately it only cost me a bottom Watt Link arm! Subsequent experience confirms that bottle jacks seem to be the least stable type should the load go off axis so a bit more care and attention to lifting geometry is desirable when being ambitious. I've been ambitous on more than a few occasions. But carefully and appropriately mindful of staying off the Gremlin Masters radar.

These days my normal approach for your sort of job with wheels on is high lift jack then slip my tall ramps underneath which gives enough room for most things.

Yeah, if I'm honest, it's not ideal. H&S would freak out if they saw me doing this at my old job...

But then again, once I have the height, I need all of 20 seconds to shove the TC under there and lower it again.
you can use cement bricks , about $3 ea , one under each wheel will give you 150 mm
Weeeellll... It's done... And it wasn't so bad once I got the car over the jack.
Pics for precarious danger death.

Usually splines and heavy things spell lots of swearing and a lot of trial and error, but it literally thunked into place within 5 minutes of jacking (off).

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And that's about it.

I'd say if I was doing it again, start to finish would be about 4 hours, and would probably take 3 if you use proper lifting shniztletrsamabobs.

The end.

Just thought I'd do a rundown of the cost:

$85 for the transmission jack attachment
$250 for the used TC from tassie
And that's about it... I had the basic tools already, and the trolley jack.
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