I'm having a hell of a time getting my transfer case bolted back to my transmission. I just installed a built shep trans by dropping the subframe/steering rack out of the car.

My main question is about leaving the driveshaft connected to the TC while trying to push it on both sets of splines w/the trans. Is this normally how you guys do it? Or do you install the TC and drop the brackets on the center diff to reinstall the driveshaft into the TC?.

I'd be grateful for any help! All the tutorials I've seen only help with disassembly

 

This is where I'm at:

 

Ok I think I may have found the problem... although I'm not sure if it is a problem.

The "output" double spline from the transmission to the tcase has 4 double spaced places with no teeth. The transfer case only has two on opposite sides.

Here is a pic of the trans you can see the area with no teeth that I'm talking about:

 

Ok so the "big" spline on the tcase has 2 of the missing teeth area... the "big" spline coming from the tcase has all teeth.

The "little" spline on the tcase has all teeth and the "little" spline on the trans has 4 spots with missing teeth.

Maybe I'm ignorant but it doesn't seem like this would mate up?

 

I had to monkey mine on for a good hour...

Here's what I did...

1) unbolt the drive shaft

2) Unbolt the aluminum drive shaft housing (4 bolts)

3) Get the drive shaft spline in the tunnel then twist and turn the transfer case to get it to line up with the splines. You can also have someone SLOWLY turn the crank with a ratchet if you need a little extra movement on the gears.

Hope this helps. I know its a PITA to get on but it WILL go on with a little monkeying. The TC is one of those parts that tests your true patience/frustrations/anger management skills on the Evo.

-E

 

Ok so it will go on... that's what I needed to know more than anything.

So I should put the tcase on without the driveshaft connected... then unbolt the housing stuff in the middle to lower it down so I can put the driveshaft back in the tcase?

 

you shouldnt have to unbolt the tail shaft housing on the xfer case. Just removing the drive shaft and rotating the back up and down should line the splines up.

The missing splines have no orientation. It wont matter where they go.

 

I had one set on but something popped in my chest so I had to let it back down. I'm freaking sore and worn out from installing the trans lol.

I'll give her another go once help arrives!

PS: I didn't unbolt the tail housing... but I'm thinking the bolts that mount the center diff may have to come out to get the driveshaft back in the tcase once it's mounted to the trans.

 

You do if you want to keep from unbolting the subframe... The TC/Driveshaft splines barely fit with it off. Don't ask me how I know...

-E

 

Take the front portion of the drive shaft off. Leave the center support bearing connected to the car. Remove the four nuts / bolts on the flange and it pops right off. Mark the orientation on the flanges so you can put it back in lined up the way it was.

 

I have never tried using a jack to lift the tc for installation. I have always just gotten underneath the car and installed it lifting the tc onto my chest. I use the oem jack on the ds to jack the engine away from the firewall for alot of room. Then the tail end of the tc goes straight up and back into the valley above the sub frame. It is easiest to get the tc on to the transmission spline by pushing the end of the driveshaft up and down while you are wiggling it on.

 

There is no way of leveling the thing on a jack... I've been pressing it off my chest too... I get it up there and star wiggling it around and my arms give way and I have to let it down.

I don't have the sub frame in the car at all right now. Appreciate the advice... I'm very excited to get the car back up and on the road again.

 

If you have no subframe on, then this should be cake...

-E

 

Thanks again folks! I managed to get it up by myself yay!

 

It would have been if I had energy! This is my first clutch/trans/tcase removal/install so it's been a learning experience.