D21 transfer case

[joshpom]

Is it very difficult to replace transfer case, anyone done it and could give me info on it!? Thanks

[will i am]

i dont no what the autos are like, but ive rebuilt a couple off these manual gboxs with new bearings
ive never done it in place

if you were trying to do it in place you would need to:
-unwind torsions then remove
-remove driveshafts
-take gearstick and 4wd shifter out
-undo plugs on transfercase
- at this stage i would drop gearbox and transfer case oil
-crack off bolts that hold transfer to gbox
-slightly drop down gbox
-undo bolts that are cracked off and remove transfer

you will need a hoist and trans jack to do it this way

[joshpom]

i got the transfer case out, and noticed that my new one is a different size, the shaft from the gear box to the trasfer case is small, where as the hole for it to go in on the new transfer case is bigger than the old one.?

[lax2wlg]

V6 Transfer case had larger drive chain and different output spline count. Talk to kbjj, apparently pretty easy to make it work. Cool mod.

edit: that's input spline.

[Dirtydog]

Otherwise ive got mine that came out of a td27t auto, if your interested.

[kbjj]

V6 Transfer case had larger drive chain and different output spline count. Talk to kbjj, apparently pretty easy to make it work. Cool mod.

edit: that's input spline.

Strip both transfer cases and swap the input gear, autos have a bigger input shaft than the manuels. The v6 auto transfer case I got has a bigger drive chain in it.

[kiwinoz]

Would the trans case in the Mistral have the bigger chain? Shaft?
And would the auto and manual be the same?