I'm in the process of removing the 46RH transmission out of my '96 Dodge Ram 2500 4x4 with 5.9 magnum and replacing it with a rebuilt transmission. I'm having a hard time separating the 241 transfer case from the transmission. I've removed the 6 nuts off the studs holding the transfer case to the transmission, along with removing the transfer case shifter, the linkage, the vacuum connector and the vent hose. Those nuts were a pain to remove off the studs due to rust/corrosion. I've been able to wedge a screwdriver in between the transfer case and the transmission, but it seems like the two top studs are welded to the transfer case due to years of road salt/corrosion. I don't believe the transfer case has ever been removed from this transmission.

Are there any tips that anyone can share to help me remove the transfer case from this transmission?

 

Rubber or plastic hammer. Sometimes I'll use a jack

 

I've got the truck on a lift and I've tried hammering the transfer case back, jacking it up and down with a transmission jack and wedging screwdrivers between the transmission and transfer case. I've got a bit of a gap going down low, however, the upper section seems quite stuck together and isn't separating. I double checked and all 6 nuts have been removed from the studs.

 

Try using a chisel with a sharp point instead of a screwdriver. If it moves then do the same on the other side until it comes off.

 

Probably want to use something with a very gentle taper..... put too much force on the stuck studs, and something may break. I used a steel putty knife between things that are really stuck tight.

 

Are you SURE you've removed all the nuts and bolts? I'm assuming you already have a new gasket for between the t-case and transmission. Do you have the same number of bolts and nut as there are holes in the gasket for hardware?

 

To my knowledge, there is no gasket between the transfer case and the transmission. There is a seal on the back of the 4wd transmission and its new with the rebuilt transmission. I triple checked to ensure all of the 6 nuts were removed from the studs that hold the transfer case to the transmission and they are indeed removed. To my knowledge, this transfer case has never been out of the truck since it was installed in 1995-1996.

 

Thanks for the advice. There is already a chunk of the transmission case that has popped off around the second stud from the top on the passenger side of the transfer case. There is rust around that stud and its still stuck onto the transfer case tight. I'll try to get a steel putty knife into the upper section to see if I can see some daylight between the transmission and the transfer case, as this is where things seem to be really stuck.

 

Great idea. I'll work that into the process.

 

If you haven't already, support the trans on a jack, pull the crossmember, and lower the trans/t-case down a bit, to give you some more room to play.