i just had my tc and transmission taken out to send to T.R.E. but my mechanice has never seperated the tc and transmission on an evo before and wants to make sure he does it correctly. we have tried calling jon from tre but can't get through, so i was hoping someone on here could help me out. my car has been down for 3weeks now and i am dying to get it fixed!! thanks guys!

 

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Transfer-case removal:
I was unable to completley remove the transfer case from the vehicle, it may be possible but I didn't do it this way
You will need a pole slap-hammer that can pull out the output shafts from each side of the tranny, these shafts are what the axles spline into
With this slap hammer you will need to find a M8x40mm bolt that threads into the end of each input shaft (MB991721 would be useful here but I wasn't going to buy this to use it once)
Then attach the slap hammer to this bolt and after a few hits away from the car the shaft should come out of the car
Remove the M8 bolt from the shaft and repeat procedure to the other side
The driver side shaft is longer, set both shafts in a safe not dirty place
The snap rings (CIRCLIP) on the shafts are the same as a 90-94 Eclipse driver or passenger axle snap ring, the only reason I am including this is because we had to search for this replacement when the dealer couldn't get us this ring the same day, we happened to break one during the re-install, and this was the easiest way to replace the snap ring, we just returned the axle minus the ring. It helps to have a friend at the parts store.

There are 6 bolts holding the transfer case to the transmission, 3 on top and 3 on the bottom
Remove the 3 bolts on the top, the hardest bolt to understand is one that is not directly next to the tranny, it is a long bolt that is closest to the rear of the car
Remove that bolt and then the other two that are next to the tranny, I removed these from under the car reaching from the passenger side to the bolts, they all face towards the passeger side
Remove the 3 bolts on the bottom side of the transfer case assembly
By lifting up the driveshaft from behind the subframe it is possible to seperate the transfer case from the tranny, a little prying may be needed but careful not to go too far into the transfer case
It now should be possible to seperate the transfer case from the tranny and now move it as far towards the passenger side of the car as possible

 

Just to add to your post.
You don't need the slap hammer.
The output shaft on the drivers side can actually be pushed into the trans as far as it goes. That way it doesn't have to come out at all.
It will stay in the trans while you pull the transfer case out.
The subframe will have to drop exactly 3 inches.

 

They got all the infomation u need!

 

Good luck and good info here but I wouldn't have had someone touch my car if they don't already know how to do it.

 

well, tey have removed all the bolts, and have pryed the two. it is still not coming apart, and he wasn't unsure if there was something special u had to do, cause he doesn't want to damamge it. has anyone else had problems with seperating there tranny and tc? he is going to try a pry alittle harder, but not place the pry bar any further in. if anyone can give any insight, i would greatly appreciate it. thanks for the quick response!!

 

Push the TC and trans together again.
Then lightly tap on the drivers side OUTPUT shaft (the one that connects to the axle)
until it is firmly INTO the trans and can't be pushed back any further.
Then pry on the web section below and the top lip of the TC above the motor mount. This will help put even distribution when prying. The TC will pop off and fall onto the subframe if you are not careful. One good pry and you got it. Make sure you pry both top and bottom of the TC at the same time with the same pressure.
Good Luck

 

well they already have it out of the car, any ideas on what to do with it already out?

 

What do you mean out of the car? The whole trans and TC?
If so same theory applies.

 

This thread is really scaring me... it sounds all too familiar.