After putting on a new trans filter and filling it up I decided to go for the transfer case; ie to drain it and refill but I can't get the top bolt out. It seems to have a black washer on there, feels like it's glued on (pretty sure it's not RTV, too hard). Does anyone have a good trick for this one, do really want to change the oil since it's darkish and leaking out a bit (not sure where yet).

 

drain it from the bottom bolt and pour in the correct amout of fluid thru the speed sensor hole

 

get a big wrench, i believe its 1 3/16 and break it loose, the black might be the old plastic washer the factory put on. and the leak is either the case halves or the front output seal. but ur rear output looks a little leaky too so that could be it

 

Which one is the speed sensor hole? The third one up in the pic, about the same size as the other?


Ok, so basically some brute force should do it? Might be a good time to drain and refill if those washers are factory ones, it has 130K on the meter. How hard is it to change the output seals (for someone who has never done it)?

 

speed sensor hole is the hole that has the plug with the orange, yellow and another wire coming out, just undo that one bolt and it should pull out. the rear is easier than the front. the rear you just pull the DS out, get a seal puller and hook onto the seal and it should come out. its a little harder than it sounds but thats it and just hammer the new one on until its flush and about even all the way around

 

Ah, ok, i see.

Ok, thanks, sounds do-able. Will put that on my, ever growing, to-do list for around xmas (won't be driving much right now so I hope it will be fine 'til then).

 

Went and got myself an impact wrench and it came right out. Some PO had put alot of blue loctite on the bolts.

 

Heat is your friend when it comes to locktite, if you know it is there.
Heck, I like heat any time I run into trouble. Heat and penny-traiting oil.
Not so big a fan of the impact gun, only as a last resort, but it worked!

I don't have a gas axe anymore, so I use the propane (or MAPP gas) and the MIG welder to heat things up.

Steve

 

You beat me to it. Impacts are handy. Always a good idea to remove the fill plug before the drain plug on anything just in case.

 

I was thinking heat as well but decided against it because of the alu casing. How do you use the MIG as a heater? I have one but have never thought of using it for that.

I'm really happy with the little tool, got a 18V one with 170 ft.lbs. of torque so I don't have to run compressor hoses. Did like you say, fill plug first.