I've removed my cross member, front and rear drive shafts, disconnected all electrical connectors and hoses and I'm getting ready to pull the case. A couple of the bolts that are holding on the transfer case look a little tough to get to so before I get down there and start at it, just wondering if anyone had any pointers or recommended (specialty) tools for the job?

It almost looked like the mid section of the exhaust might have to come out to get to one bolt on the passenger side due to lack of space down there. (I'll have to look closer.)

Thanks in advance for the advice.

 

You don't have to take the exhaust out if you don't mind a hand cramp.
It's just a slower process cause you can't turn your wrench all the way.
A ratcheting box end wrench will air your life easier in this process

 

That's actually the one wrench I don't have, so I'll probably stop and pick one up on the way home tonight. I'll give it a try and asses the exhaust situation while I'm down there with the new wrench.

Thanks for the reply.

 

9/16 flex head gear wrench

some people like the stubby too

 

And the winner is... stubby. Made a quick run to Home Depot and picked up a 14mm stubby ratchet wrench and it worked like a charm. The case is out, and now the real fun begins.

 

Thanks for posting the proper size so others can be prepared for that job!

 

Keep us posted on what needs to be done, also with photos. I also have a 242 TC


Mike

 

I got a G2 overhaul kit, new chain, oil slinger and pump. I figured if it's apart why not do it all? When I emptied the case before pulling it the fluid was practically brown so that just makes me feel a little better about the decision to go all in, I'm pretty sure it's been a while since anyone has thought about the case. I'll take pics and post here when it's all done.

 

good set of teardown and rebuild pics

good pics of parts and where they go


also the FSM has extensive instructions

 

I've seen those videos but I haven't seen those pics. Both are very helpful, thanks for sharing ehall.

 

WTF! Was that dude making the vid on a ship? It made me seasick looking at it so I shut it off. LOL