Needing to pull the transfer case to replace the front output bearing. Has anyone here pulled one out of the 2004 1500 4wd. It is a 5.7 Hemi, 545RFE Trans, NP243D Tcase.
I am mulling over a few things planning out the job. Some advice would be helpful:
- if the crossover exhaust pipe has to come out
- which joint to separate at the transmission, just the Tcase flange or easier to take at the extension piece joint on the transmission
- the rear support looks like it blocks Tcase bolts, does the rear support cross bar have to come out. This truck has torsion bar front suspension, the bars pass through there.
- what is the best way to jack and block the transmission when the rear support is taken off. Safest point on the transmission to lift
- it looks like there are no engine/transmission mounts other than two at the front of the engine and one at the back of the transmission/tcase joint. So the whole thing is going to drop if not held by jack or blocks, correct?
- What would be the breakdown of the steps 1 2 3 4 5 ..., any tricky points, any tips?

Looking to get into it over the weekend.

 

No one? Surely someone here has done this job. I am not asking about a tcase rebuild. I am only asking about the most efficient and safest way to remove it from the truck. Time is not a factor.

 

Its actually pretty straightfoward. Drop the rear driveshaft, disconnect the front shaft from the t-case, pull any linkages/electrical connectors, and unbolt it from the back of the trans. I don't *think* there is a mount on the case itself....... Then just slide it back off the input shaft, and it'll fall out. (it's not exactly light, so, be careful. )

 

This one isn't quite as straight forward as that. The way the support perch is, makes it impossible to get to some of the bolts. I can figure it out, sure enough. Was wondering if anyone had tips/tricks for this configuration. Here are some pictures that might help clarify what I have to deal with.

 

Oh, that looks like fun..... Dropping the lower part of the crossmember might make it easier..... maybe a long extension, and a wobble socket? Not sure if you are going to have to drop the exhaust.... you might be able to move the t-case back far enough to disengage from the input shaft, but, whether you have the geometry to drop it out of that hole is another question entirely.

 

Imma thinking wood blocking under the transmission pan, to hold the transmission and engine up. Then the cross member and perch will be coming out as one piece, taking 4 bolts out. Once that cross member and perch come out there is nothing holding the engine or transmission other than two motor mounts at the front of the engine above the front axle.
Then I can get at all the Tcase flange nuts. From there, slide it back and then maneuver it down through where the space where crossmember was. Should be pretty easy ... I think ... I hope.

 

Good Luck.

 

im doing this now. Same setup. 2004 Ram 1500. How did you do it please

thanks for any help

 

Hi I'm doing it also one mine, how did it go, do you have any tips? Thanks !

 

Just run a ratchet strap from frame rail to frame rail cradling the transmission and drop that crossmember. No need for wood blocks and extra jacks in your way. (I've used ratchet straps before to solo sling a 545rfe in, it works)