I have a 1998 Ram 1500 5.9L 4x4 with a 46RE trans and NP231 Transfer case. I'm trying to remove the transer case to rebuild it, but it's stuck pretty good to the transmission. I have remove the trasmission mount, crossmember, all 6 nuts attaching the case to the transmission and everything else attached to the transfer case. It won't budge. I'm thinking there's alot of corrosion inbetween the case and the trans. I've tried everything I could think of short of using a hammer and chisel between the cases. I even tried a come along between the rear differential and the case and it still wouldn't move. I don't think I missed anything attaching the 2 together. Anyone have any suggestions that might work?

 

Welcome to the Forums.


There is a search feature you can use at the top of the screen. I remember reading about this same problem in a previous thread around a month ago, but dont remember the process.

The answer is on this site already, just use a search. This is what most will tell you to do. sorry i dont have the answer.

 

I've tried searching for this problem but haven't any luck. There's a thread from a month ago that I did find about removing this type of transfer case and it has alot of good info, but the case stuck to the trans wasn'tone of them. I'll keep looking, though.

 

are you sure you got ALL the nuts? even the ones on top?

 

6 would be all of them....

It's probably been sealed with RTV.. Pry it apart and avoided damaging the sealing surface.

 

I can't even get it apart enough to get a pry bar between the two. The thing that lead me to them being corroded together is on 3 of the 4 bottom studs (I can't see the top 2) the space between the studs and the case are completely full with rust. Anyways, thanks for the input and I'll keep trying until something works.

 

you could try getting a jack underneath it, and jacking the transfer case up and down to try and loosen it. that might help, just dont over do it haha

 

Maybe spray some penatrating oil like PB Blaster around all the studs, let it set awhile to let the oil do its thing then try the jack thing

 

^PB isnt a good penatrating oil, but the bolts are off so it will clean them a bit

 

I finally got it off. It was all corroded inside and at some point the drain hole plugged up. Here's what I ended up doing. At the studs located at the 6 o'clock position and 9 o'clock position (drivers side) the transmission case overlaps the studs. I took the mount nuts and flipped them over (washer side towards trans) and screwed them back on. Then I took 2 1/4 drive sockets and placed them between the nut and the transmission and started to unscrew the nuts. This worked to push the transfer case away from the transmission. At the 3 o'clock position, your unable to do this but part of the transfer case is exposed and I used a drift and hammer on this side. I wasn't able to get anything on the top, but working all 3 of these positions a little at a time and I was finally able to get it off. I don't know if it was ever off before I took it off, but I'll definately use anti-sieze when it goes back on. Hope this helps someone in the future and thanks for all the input.