I've already got all the seals for the trans, and xfer case. Im gonna replace them all when and if i get the darn thing out. I got the trans mount out today, busted 2 of the mounting bolts doing so, i lowered the xfer case, still not able to get to the bolt. Started taking off the 4X4 shift lever to try going through the cab, but like everything else on this truck, its either hard to get to or the bolts are seized. Im on the verge of giving up. Its really a shame that all that is holding me up is 1 lowsy nut. Ive hosed everything down with PB Blaster, But not holding my breath.
GRRRRRRRRRRRRR

 

Take your time, and take deep breathes when your working on these trucks. Also, where available, use heat! You don't need excessive heat, but think about it this way, all those bolts down there heat up and cool down with the trucks heat cycles. All that expansion and contraction can be horrendous on bolts

Also, like I said earlier, the only seal that is between the transmission and transfer case is the "Output shaft seal" or whatever your local parts store wants to call it (came across a few different names based on stores....)

 

Success!!!! The xfer case is out, it is much simpler to go through the 4x4 shift lever hole in the cab, once i got all the nuts/studs,(The studs came out instead of just the nuts on a couple), the case came out suprisingly easy which is a relief considering everything else up to that point as been a pain. As you stated Crazyjerry, there is just a regular seal between the 2. Gotta pick up some degreaser and clean off the transfer case, and start figuring out how im gonna get it installed by myself......lol. Thanks for all the help, and suggestions.

 

get some help to put it back in. it can be done with one person if you know how but you risk dropping it or damaging something. i lifted mine in myself without a jack but its no easy task. i would probly put the studs back in the tcase first. replace all the seals while its out on the ground. actually the tailshaft seal isnt a big deal and can be installed after the tcase is bolted up or before. doesnt really matter.

 

Sadly its only me, if it drops it will only hit the ground, I dont have a garage ,yet, unfortunatly.

 

I started cleaning up my transfer case, it was pretty greasy, after cleaning i was inspecting for cracks, and noticed dried RTV gasket sealer on all the seams, and non mopar seals, so it makes me wonder if it has been rebuilt, and why had it been rebuilt. Not sure if its a good or bad thing.

 

mine has red rtv on all the seems and i believe it to be original but not sure. maybe someone that purchased one of these trucks brand new could answer that question. some of the original seals will probly have a chrysler logo but im not sure if all of them will.