So I have the transfer case back together but I don't have a front driveshaft on at the moment. 1 thing I did notice is it goes into gear a lot harder now (have to shut truck off to go in 4L) it never did this before. With the front driveshaft off and in 4H or 4L with the transfer case working, it doesn't make any noise no matter how hard I try. I know there's no power to the front wheels but I would still think it would make some sort of noise if it was the transfer case.

 

There is no load at all on the front drive section of the t-case. If you had a chain slipping, or something along those lines, it won't show itself until the front driveline is loaded as well.

You did put fluid back in, right?

 

Yes I did!! Any idea as to why the transfer case is shifting like a normal 231D now unlike before where it would actually shift nice?

 

Did you replace any parts? Adjust any linkages?

 

I replaced the range fork pads but that's it. I'm going to put the front shaft on the truck when I'm home on Wednesday. I'll let you guys know what's up.

 

So before I can put back on the front drive shaft I have to fix this



Anyone got any ideas? I've tried soaking and heating it up and using vice grips which didn't work. Drilling it out is a possibility but I don't have a drill press

 

That sucks. I thought heating it would have worked. Maybe you could weld something to it or just drill it out. Whatever you do though don't use an extractor.

 

Channel locks and vise grip the handles.

Real channel locks and real vise grips

I was gonna tell you I have one I would give you but then I realized it was the part on the axle and I don't

 

Those holes go all the way thru don't they? If so, put in some PB Blaster from the BACK. Let it soak in for a bit, then heat the yoke around the bolt so it glows a nice shade of red. Grab 'em with vice grips, and they should come right out.

 

Okay I will try some stuff this weekend. Have it soaking right now