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My transmission to transfer case flange broke..

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Old May 14, 2021 | 03:00 PM
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Default My transmission to transfer case flange broke..




Second picture kind of useless you can maybe see the transfer case 'sleeves sticking out.

I'm not positive how it happened. The cab shakes pretty bad due to an exhaust manifold leak, I think it shook the lever into 4WD while I was going up an on ramp.

Was able to tow it home and drag it into my driveway where it has sat. I cant get the thing out. I haven't beat it senseless yet, but I have all the bolts out..

Is my transmission salvageable? I can weld if that helps me out here. The pieces of the flange are shattered on the side of the road somewhere.

Transfer case is shot?

Drive shafts reusable?

 
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Old May 14, 2021 | 03:06 PM
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Pics aren't real clear, but, it looks to me like the back part of the trans broke, and is still attached to the t-case? If so, you can just replace the O/D section of the trans, and call it good.... but, I would be nervous about that. Would be more inclined to replace the entire trans....
 
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Old May 14, 2021 | 03:07 PM
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Having a lot of trouble removing the t-case and drive shafts. The main deterrent for me is the support arm that comes down off the bracket that, supports the transmission mostly but also the transfer case. Pictures 3 and 4.

I have left the skid plate on, because the transfer case is just sitting on it. I can move the case in every direction, its broken off the transmission. Im about to go ahead and remove the plate to help dismantle it further.

I'm having so much trouble because all of this stuff is supposed to be stiff when removing the drive shaft I imagine? Should I just pull out the cutting wheel at this point?

Pictures 2 are those 4 little 3/8 holding 2 bractes on. I have those off on front and back.. Picture 1 is the bolts I took off to remove the rear shaft from the transfer case but it just slides in and out won't remove.

Any help is appreciated thanks guys

 

Last edited by Ramchie; May 14, 2021 at 03:11 PM.
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Old May 14, 2021 | 03:09 PM
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Originally Posted by HeyYou
Pics aren't real clear, but, it looks to me like the back part of the trans broke, and is still attached to the t-case? If so, you can just replace the O/D section of the trans, and call it good.... but, I would be nervous about that. Would be more inclined to replace the entire trans....
Wow that would be awesome I hadn't realized that!!!

Let me take some more photos to try and show you more clearly where the break is before I get my hopes up..

 
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Old May 14, 2021 | 03:14 PM
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For the rear shaft, need to drop the differential end, and then the shaft will slide out of the t-case. No need to remove any bolts on the t-case.

The front shaft is gonna be fun, as the bolts are probably REALLY in there, and the case is going to flop around when you try and break them loose. An impact would be real nice to have for those... or, just disconnect the shaft from the front diff, and take it out with the tcase... (careful though, you just know that shaft will take every opportunity to thump you, given even 1% of a chance.....)
 
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Old May 14, 2021 | 06:40 PM
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Originally Posted by HeyYou
For the rear shaft, need to drop the differential end, and then the shaft will slide out of the t-case. No need to remove any bolts on the t-case.

The front shaft is gonna be fun, as the bolts are probably REALLY in there, and the case is going to flop around when you try and break them loose. An impact would be real nice to have for those... or, just disconnect the shaft from the front diff, and take it out with the tcase... (careful though, you just know that shaft will take every opportunity to thump you, given even 1% of a chance.....)

Man there's something I'm missing to removing the rear shaft. I have the front disconnected. The very rear connection is hanging on tight. Keep on mind the rather heavy transfer case is just sitting on the skid plate.. I have it moved up towards the front past where it was connected to the transmission, albeit about a foot below where it was connected. I have tried prying it off. I just have the truck sitting with chucks, would jacking it up help somehow?
 
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Old May 14, 2021 | 07:33 PM
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U-joint doesn't wanna come out of the yoke? Yeah, seen that before..... Big pry bar is about all you can do.
 
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Old May 14, 2021 | 07:34 PM
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Jacking up the rear and supporting both sides with jack stands may help, as it may be in a bit of a bind. Once you have the rear jacked up, you should be able to insert a pry bar or large screwdriver behind the rear U-joint to pry it forward to release the driveshaft from the rear.
 
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Old May 14, 2021 | 07:46 PM
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Any reason why the 4 bolts are removed from the extension housing at the rear of the transfer case? Those 4 bolts do not need to be removed to remove the rear driveshaft..
 
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Old May 14, 2021 | 09:06 PM
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I'm not sure an exhaust manifold leak would make truck shake and going into 4wd, even on dry pavement at speed, shouldn't cause this

I'm still struggling to make heads or tails of most of the pics but I wouldn't panic yet. I think it might be repairable....
 
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