Any tips on lining up the torque converter to the flywheel, as far as the four bolts? Should I install with the transfer case on or off, its like 100pds. lighter with it off?

 

install with the TC on. and no real trick except make sure you get the dowel pins on the block to seat to make sure the tranny lines up right. then use a pry bar to turn the flywheel to line up the bolt holes...

 

I'd mount them separately. First, I'm assuming you haven't installed the tranny yet. Hold inward pressure on the Torque Convertor as you spin it and you will feel it seat into the pump drive with a "clunk" sound when it does. When fully seated, you shouldn't be able to get your fingers between the back of the Torque Convertor and the pump drive mounting flange.
After the bellhousing bolts are attached, you can slide the Torque Convertor forward and install the flex-plate to Torque Convertor bolts. Then you can install the t-case without worrying about getting the Torque Convertor aligned, as you would if you installed the trans and t-case as an assembly. JMO
Dan

 

its heavier but easyer to put the transfer case and the trans in together. the bolt to that hold the tc on are hard to get to under the car. as for lining the torque converter up just jack the trans up in place and when u are sliding it into place have someone turn the crank pully bolt with a wrench and it should help the center pin line up and slip in. if u have some greese u can put alittle on the shaft and that should help to. i just put a trans in my jeep and i had a hell of a time tining up the center shaft on the torque converter.

 

I have put them up both ways with and without the transfer case. The hardest part is the torque converter alignment with the flex plate. Antiseize both the end of the crank and the torque converter plug. This will allow easy mating of the converter and flex plate and allow them to come back apart if needed. I also put some long all-thread rods from the block screwed into the two bolt holes near the pins, to assist with the alignment of the entire transmission to the block. It always seemed that the first time without the rods the transmission had to pivit one direction or the other just a small amount. When trying to get just that small amount of twist you over did it and you would have to try again. The rods allow you to line the tranmission early on so it is just a straight in shot with just a small amount of up or down right or left to get the flex/torque system together.

Have fun!

 

great tip on the alignment pins! I will go to the hardware store and get two long bolts of the same thread size, then cut off the heads.