Help please. My first post here. I am trying to remove the transmission/transfer case on my v6 4x4 with automatic transmission. Couple of problems so far. The exhaust cross over pipe was a real pain, broke bolts and not much room to work. The manual says to remove the transfer case... okay makes sense as the cross member that the torsion bar connects to is in the way of the tail shaft. The upper bolt between trans/transfer case on the driver side won't back out all the way! There is a shift link bracket that blocks it. The bracket has 2 bolts on the side (would be easy to remove) but has another bolt on top that seem impossible to remove with trans in place. If I can't seperate the transfer case do I have to remove the x member for the torsion bars to drop the transmission/transfer case?
Thank you
Bob

 

Not sure but if it's anything like my '95 the torsion bar cross member is permanent. Just take your time and get everything taken off. I worked on a '94 1500 that has those shift rods/linkages. They were a PITA, so I know what you're talking about. Just get as much as you can out of the way. I'm pretty sure you have to separate the t-case and the trans to get it out though.

 

For the bolt on the top I pulled my shifter boot on the inside and went down through that way. It is a pain but be patient and you'll get it. Also, whe you get the t-case bolts out and are tryingto drop it down be flat on your back(if your like me and are on the ground) and be ready to catch what feels like 60-70 lbs. Mine was quite heavy and wanted to fall to the drivers side. By the way if memory serves me correctly the bolt on the top of the t-case is an 18mm. Good luck and keep us posted.

 

1. drop the transfercase and transmission as a whole.
2. drop the jack down a little lowering the trans to access teh top bolt because it is a bracket for the four wheel drive.
3. make sure all your linkage and wiring harness and Trans cooler lines undone or out of the way.
4. remove the exhaust Y- Pipe after your remove the cross member.
5. the crossmember isn't difficult to take out, it needs to be twisted out in other words one side high up and the other down twisting it out. It may take some effort but believe me putting it in is a piece of cake.
6. no need to move the torsion bars as the might appear to be in the way just twist it the right way i had to pry mine out with a pipe. after words knowing how easy it was i hope i save you some time.
7. when you put the trans in make sure the trans and t-case is assembled already and start with the tail of the t-case up first. i hope this helps solve some problems.

 

What size is the bolts that hold the crossmember to the frame rails? there's two on each side.

 

They should be 15mm.

Pretty sure you are done with this project but I want to help out others.