Installing transfer case

[rrefx]

Hey guys,
I'm installing a transfer case in my Mom's '96 Disco. I haven't installed one before, and i didn't take out the broken one, so I may have a few questions as the day progresses.

First off, does there need to be any gasket material between the transfer case and the transmission, or does it just mount up flush without it? The gasket kit I bought doesn't seem to have one that fits that surface, but I couldn't find anything in the manuel about it needing one.

Thanks,
~Ryan

 

[JR Ewing III]

On my '03 Disco there was no gasket material between the transmission and the t-case.

 

[rrefx]

Thanks man, now next question.... I'm having one heck of a time to get the T case to slide on the gear... I made a block for my jack according to the specs in the manuel, but I'm worried that I'm gonna damage teh seal trying. Anyone have any helpful advice? The manuel mentions some kind of guide system, is this something I can quickly make?

Also, the transmission, when on a pretty good down angle, leaked a little oil out of that rear seal, but teh seal looks like it's in good shape, I hate to think it, but this will mean I have to replace that seal I guess, any tricks for getting it out, and a new one on with that big gear shaft right there?

Thanks again,
Ryan

 

[rrefx]

All right... I am compleately lost now with all the linkage, different bolts, and spring. I really wish I had been the one who took it out, but my uncle decided he was going to be all helpful while I was away working on a show in Kanab, took it out, and then he moved to Montana without finishing the job. He wasn't the most organized in doing it either. Does anyone have a diagram of how the linkage etc. goes together? I have a maintanence manuel, but it doesn't go into much detail with how it all goes back together.

Thanks,
Ryan

 

[Lutzgaterr]

don't you have a manual?

 

[ShaunP]

Remove the input drive gear from the transfer case prior to fitting the case and put it in later, it just slides in, this way you don't need to line up the splines. If you remove the pto cover and bearing carrier the gear will slide out the back of the transfer case.