So i just finished putting the motor/tranny back in the car after getting my motor built and trans back from shep. Everything went on smooth except for the clutch fork being really hard to push for some reason? My issue is that I cannot for the life of me get the damn TransferCase back on. It's clear of all obstructions so it should just slide right on. I wish it would just follow that theory Is there something I am doing wrong? It's lined up perfectly just will not push to the bell housing. I don't want to break anything so I haven't tried using muscle. I don't remember it being particularly hard to break loose when removing. Someone please help, It's been 3 months since I've felt a turbo kick in and I'm going through some serious withdraw.

Also, about the clutch fork, is it hard to push (to driverside position) because it was dry being installed? I forgot to put a little oil on everthing when installing. Figured it would jsut lube itself when filled with fluid.

 

hopefully the fork is facing the correct way or you're screwed.

do not put the rear motor mount bolt in until the tcase is on

 

Why would it face a different direction? It looks like it's in the same direction as the last tranny I had. I used the same TOB and fork that you sent it with (bought the transmission from you actually)
As for the mount, I haven't bolted it on yet. The issue I'm having just seems like an alignment thing with the splines. Looks like the first set of spline slides in but once it hits the 2nd set it stops. Is there a way to turn them to align them? I've tried to make small adjustments everytime I pull the TC away from the bell housing but nothing works. I don't want to start banging **** around and damage something. Everyone I talk to says this is so easy but I worked at it for over a half an hour before having to leave for work. Nothing

 

with the front and rear motor mount out you can rock the trans and engine forward and back while sliding on the transcase. Hopefully the downpipe and licp are off

 

First make sure u didnt double up on the alignment dowel pins.

Second u need to rotate the shaft in the extension housing on the transfer case. U will feel the splines line up as u rotate it and it will slide in. As you rotate wiggle the t case so the splines line up.

 

what do you mean by double up?

 

The splines probably aren't lining up. Doubling up on dowel pins, I don't understand that either lol

Also, make sure you have an o ring where it's supposed to be between the tranny and the tc. Otherwise you'll get major leaks, and could cause your tc to eventually fail.

 

Update: Decided to take everything out of the car one more time just to double check and make sure everything was right. I had a weird feeling about that clutch fork not moving much and figured I would just double and then triple check everything. We got everything out and went to pop the TOB out. While turning the flathead to pop it out..something popped and after that the fork will no budge in any direction no matter what we try to do. Something definitely wrong at this point. I've made a few calls and now it seems as if the only way now is to unbolt the pressure plate through the various small holes in the bellhousing. FML...

I still have no idea what went wrong. Everything lined up correctly and the transmission went into the flywheel no problem. The fork was on the correct way (I checked my old transmission to verify) and the TOB looked ok before installation. I'm stumped now. I'll be taking it to SSP in houston later this week to have them seperate it. Wish me luck

As for the transfercase, I'll try turning the spline when it comes time to install again. Thansk for the advice guys. I can't speak for everyone on this site, but I know that a lot of people would be in a bind if it weren't for the user input on here. You guys rock

 

There is a rectangular breakaway on the case you can cut out with a hammer and flathead to access the 12mm bolts for emergencies. The Trans will come off after you remove these 6 bolts

 

It also sounds like your throw out bearing is attached to the clip already that is why it would be hard to move with your hands once the Trans was on if it wasn't connected you would have not problem pulling the Trans off hook the slave cyl up and press the cluth to see if the clutch engages and disenguages. Then you can go back to putting in your tcase

 

I usually move the back housing of the acd/driveshaft up and down with one hand and push the acd on with the other. That gives you quite a bit of vertical movement to line up the splines.

 

Never mind. I was thinking about the transmission. T case has no dowels.

 

where is this at? I'm trying to picture it in my head and am drawing blanks? Are you talking about the 6 flywheel bolts??

 

Looks like we might have to try that and remove the clutch from the bell housing

 

Yeah seems like it. I'm still wondering what he was talking about the rectangluar breakaway point. I can't find it on any of the service diagrams. I'm going to feel real dumb if he was making a funny