any one know how to get a broken bolt out of there transfer case with out having to remove the transfer case? I was replacing the t switch on my 2005 blazer and it broke off
also is it OK to drive with out one?

 

Three button or four button dash switch? On the three button, I would say it's fine to drive, you just won't have 4wd. And you might want to cap off the vacuum lines, so as to not have a small vacuum leak.

If you have the four button, I have no idea, I'm not familiar with those cases

 

This switch is only present on the 3-button system.

It is going to be interesting to get that part out of the tcase. If you get lucky, you will find an ez-out that fits just right and doesn't protrude in far enough to hit the shaft that actuates the switch. If not, you will probably have to modify one by cutting it down so it fits appropriately without hitting the shaft inside.

As far as driving it without this switch in place, it is possible that you will lose fluid as it slings around inside the case. It is also possible that contaminants will make their way in through this hole as well. If possible, I would suggest finding a plastic plug that fits the hole to limit these possibilities.

I thought I had an old switch that I cut apart years ago for a 'how it works' thread I created, but I couldn't find it this morning else I would provide you with measurements to assist in your efforts. You can either cut apart the old switch or simply measure the diameter of the metal pin in the middle of the switch with vernier calipers. This measurement will give you the small size starting point for the ez-out.

The most challenging part of this whole thing is accessing this location. It is all going to be done through feel.

Good luck!

 

Oh, OK. Good to know!

Also, good points about fluid escaping, and possible contaminates getting it.

Also, like you said, repairing with the tcase installed on the truck is gonna be next to impossible

 

Thanks for the help will probably just cap it off as I am using it for a daily

 

You can also bypass the switch all together if you need 4wd. Unplug the vacuum hose from the vacuum source that runs to the t case switch. Run a hose from the front axle actuator diaphragm ( it is under the battery) to the port that has been vacated by t case hose you just disconnected. This bypasses the switch and locks the front axle in when ever the engine is running.

Still push the 4wd button in the cab as needed. And now you have 4wd until you get the switch issue resolved.

Good luck

Bill