I was working on the transfer case motor last week and this caught my eye.
I put a pry bar between the shaft and transfer case and turned it out towards the side as opposed to pushing on it. The shaft popped out after I built enough nerve to go for it. The front u-joint is simple to replace and costs under $25.00. The u-joint caps popped off sooner than I could react and it was easier to replace than finding needle (bearings) in a hay stack. The encoder motor bolts are thread lock soaked and tough to turn by hand.

 

funny, i coulda swore i saw that posted up there already.

 

well, work keeps getting in the way of me doing this but I will try it tonight. Does the shaft pop back in pretty easily? I already have the bolts out of the transfer case motor because I was hoping that I wouldnt have to remove the shaft. Nothing is ever easy on this truck!

 

I just redone my tcm too. I found once i got it out it was no problem at all getting it back together.

 

The shaft will pop back on easily then just bolt up the u-joint

 

Okay guys! I appreciate all of the help so far but I have one last issue. I got the shaft off just fine but now I have to put the new tccm on but it is in a different position than the pin is on my transfer case. How do I get them to match properly? can I turn the pin or the rotor that the pin fits into on the motor? Thanks guys!

 

You can rotate the shift sector shaft in the transfer case to match the positioning of the new encoder motor. DO NOT attempt to turn the motor.

 

good to know. i've never had the pleasure of changing the encoder, but you never know when it could go.

 

I am in the process of doing the same thing to my 2003 trailblazer. I got the 4 bolts out, pryed it out the yoke and am having a pain in the butt getting it out of the transfer case. So if I just pry it, it should work from the shield and t-case? Ok here goes nothing.

 

Yeah.......It doesn't feel like it will come out but it does. Once you start prying, it will pop right out. Good luck!