Installing tranny/transfer case as one

MattW · Sep 7, 2010

I managed to get the transmission and transfer case as a unit uninstalled from my Bronco to put in a new clutch yesterday. I had a friend come over in the evening to help me put the combo back in. Turns out that bastard weighs more than we anticipated.

Anybody have any ideas or am I looking at splitting the two apart and then putting them back in? We've tried the transmission jack route and quickly remembered that we swore that POS off the last time we used it on another truck.

If I do have to split thew two I've read that to leave the adapter attached to the transmission. What else do I need to worry about? How easy (or hard) is the process to take them apart and put them back together? An idiot proof step by step process for this would be great. I'll spend the day reading/researching other threads and letting my back heal.

Steve83 · Sep 7, 2010

If you split them, have a flat tool ready to slip in there to keep the input gear in the t-case so the roller bearings don't dump out.

I just did something similar on a '93: pulled the E4OD/BW1356 back & dropped the torque converter to change the front seal. But I never let them off the jack, or even down - they stayed as high in the tunnel as I could keep them.

I'd get a good jack (with trans adapter if necessary), strap the assembly to it, and lift it into place. I had to adjust those straps frequently both ways, but it was worth it NOT to have to handle that trans.

70_Steve · Sep 7, 2010

I managed to pull and reinstall my 3-speed/transfer case combo as one unit several times. As it turns out that combo will balance pretty well on the adapter. I made a "fixture" out of a 2x4 and a couple 1x2's on each end, to sit on top of my floor jack and fit to the underside of the adapter.

When reinstalling by myself, it took a bit of doing to block the combo up high enough to get it to sit on the floor jack, but I've done it.

Disclaimer: Probably not the safest operation. Do at your own risk!!

ep67bro · Sep 7, 2010

I did a C4 and tcase install in one peice and it sucked!! I used a floor jack and some help form my brother inlaw. I also did my NP-435 by myself and then bench pressed the trans case on after. I think it was easier than doing it all at one time.

MattW · Sep 7, 2010

Steve,

I take it you have to have the tranny crossmember out to reinstall as one unit, correct? I have mine out now and don't see how the transmission would slide over it, but I've been wrong more than once.

Also, the transmission is the factory manual 3 speed. Forgot to mention that earlier.

70_Steve · Sep 7, 2010

MattW said:
Steve,

I take it you have to have the tranny crossmember out to reinstall as one unit, correct? I have mine out now and don't see how the transmission would slide over it, but I've been wrong more than once.

Also, the transmission is the factory manual 3 speed. Forgot to mention that earlier.

Yes, the crossmember need to be out. I install the tranny (yes, stock manual 3-speed), then block up underneath the tranny to move the floor jack out of the way. Then reposition the floor jack under the transfer case until the crossmember is installed.

I have a pile of lumber scraps (6x8, 2x4, 1x2, various plywood scraps, etc) just for blocking up stuff.

dbevans2249 · Sep 7, 2010

I have a cheep Harbor Freight Transmission Jack that works fine after I put some "Wheele Bars" on the back. I used it with my NV3550 / D20 put together. It would fall over backwards with out the "Wheele Bars" though. It is kind of square with a screw jack that uses a ratchet to operate.

johnmlebel · Sep 7, 2010

i also did mine in one piece by myself it was very hard and i struggled big time

lonesouth · Apr 29, 2011

man o man, am i looking forward to trying this now!

so is there enough room to attach the t-case shifter after the combo is installed? I was planning on lifting from the top through the shifter hole and then attaching the shifter after everything was bolted in.

trailpsycho · Apr 29, 2011

Ive done the NV4500/D20 as a combo before using a tranny jack. Its tough to get aligned, esp. since there really isnt a "correct clutch tool" for this setup...tape on the end of the Dodge/chevy tool gets you really close, but its hard to get back in.

Borrow or rent a tranny jack if you can...it should be no problem. If you try to muscle it in without. Uses some ratchet straps around the frame to take the weight off so that neither of you can/will drop it on the other...just make sure they dont limit the "approach".

Now installing the D20 is a breeze by itself.

Good luck.

lonesouth · Apr 29, 2011

i'll be doing a C4/20 combo. Figuring on extensive use of ratchet straps and a floor jack, as well as the cherry picker from above. I do have a 1" body lift, so that should give a little more room to move.

MattW · Apr 29, 2011

lonesouth said:
i'll be doing a C4/20 combo. Figuring on extensive use of ratchet straps and a floor jack, as well as the cherry picker from above. I do have a 1" body lift, so that should give a little more room to move.

This is pretty much how I did it, only I used a come-a-long and my cage. Kicked myself for not trying it earlier, it went in without a problem with lifting from above.

lonesouth · Apr 29, 2011

I got it into position on the ground tonight. I don't have a cage, and i'm not sure I can get the cherry picker in lift. Maybe a 2x4 resting on the top of the doors(through the windows) will work.

marty · Apr 29, 2011

what i used was a atv/motorcycle jack with a piece of plywood. as for the tranny and the transfer case i used a short piece of threaded rod through one of the crossmember holes as a leg to hold the tranny straight.

John Marinan · Apr 29, 2011

Once you get close, if it's not supported by the frame, you adjust the vehicle height with tire inflation. It really helps with that last little tweek.

av bronco · Apr 30, 2011

I got pretty good at r&r tranny-transfer case right after I put my stroker in, for a c4 it's way easier to seperate them, you can bench press the transfer case up, it isnt as heavy as it looks, and the bolts and shift linkage are easy enough to get to. Be careful of the trans/transfer case gasket tho, learned that the hard way.

rockingm82 · Apr 30, 2011

I hope it goes better for you than I. It took three of us almost 8 hrs to get it in. We had to remove the exhaust, release the motor mounts, hoist the motor to get it at an angle, and tweak its alignment with a 2x4.

http://classicbroncos.com/forums/showthread.php?t=183643

Here's an earlier thread.

lonesouth · Apr 30, 2011

the engine is not installed yet.

So far, in about 2 hours, I have gotten it into position. I've got one bolt normal bolt and two long bolts on the driver's side. Ran a ratchet strap under the transmission in front of the oil pan, and another under the rear output shaft of the t-case. Used my floor jack to move either side and then cinch up the straps, move to the other side and repeat.

My biggest problem is that I run out of range on my jack and have to block it up. The t-case also made the whole assembly want to roll, but this can be used to your advantage. Jacking the t-case will cause one side of the crossmember to tilt, then cinch the strap and block the high side of the crossmember, move the jack over the low side.

I haven't encountered anything really hard yet. and I think the rest will go together pretty easily, just need time to get it done.

MattW · Apr 30, 2011

rockingm82 touched on it, but I had to use a floor jack under my oil pan to get the final 1" or so to go in when I was stabbing the tranny in. It didn't take much pressure at all, but it was the icing on the cake to wrap up that job.

rockingm82 · Apr 30, 2011

Glad you got it! I remember we started with an ATV Jack which wouldn't get it high enough. Swapped to two floor jacks. One on the tranny and one on the transfer case. Realized the exhaust was in the way. Removed that. Got it all lined up and realized that the old T shifter wasn't functioning. Hmmm???? Yanked that off and grabbed the T Shift from the donor. Once again aligned with the motor, but now blocked by the cross member. I thought for sure the book said install with tranny/transfer case/cross member all hooked up. Alright, fine, pulled off the cross member. Finally, a straight shot, but wait, not yet, the jacks won't go high enough and what's this? The engine is cocked sideways on old motor mounts. Remove motor mount bolts, hoist the front of engine, line up the jacks so the angle matches the motors dangle and 7 hours later with a little 2x4 persuasion Tahdah, it's in.

Installing tranny/transfer case as one

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