***Official WA Chat Thread***
I'll try to e-assist as much as I can, lol.
The transfercase, I think there are 7 total bolts that need removing from the case itself, but you also need to remove the housing on the back (4 12mm bolts I think) where the rear driveshaft went, for clearance.
Then, the 2 19mm subframe bolts (might be other size, can't remember) at the rear of the suspension subframe need to be loosened, do not remove. Once they are almost off, you can use a crow bar and pry the engine forward/up, and the transfer case will drop out. Takes 2 people to do it, unless you really want to stress and try to do it alone. One person to work the crow bar (pry against the engine and suspension subframe), and one to wiggle the transfer case and drop it out.
Be careful though man, it weighs like 70 pounds.
The transfercase, I think there are 7 total bolts that need removing from the case itself, but you also need to remove the housing on the back (4 12mm bolts I think) where the rear driveshaft went, for clearance.
Then, the 2 19mm subframe bolts (might be other size, can't remember) at the rear of the suspension subframe need to be loosened, do not remove. Once they are almost off, you can use a crow bar and pry the engine forward/up, and the transfer case will drop out. Takes 2 people to do it, unless you really want to stress and try to do it alone. One person to work the crow bar (pry against the engine and suspension subframe), and one to wiggle the transfer case and drop it out.
Be careful though man, it weighs like 70 pounds.
I would venture to say if it's just like pulling it off on my gvr4..
-Have a couple of the bolts still in, not all the way, just threaded in some.
-grab a rubber mallet and start pounding around the edge where it seats against the transmission. Occasionally try to wiggle it, eventually it will get loose enough and you can remove the couple bolts you still have in and it should come right off.
You can use a flat head to try to pry it, but I would be super careful and wrap a rag around the head as to not gouge out the surface on the tcase or transmission. The transfer case can be a pita. Reason I left a couple bolts in, I didn't want it falling on my face or on the ground!
-Have a couple of the bolts still in, not all the way, just threaded in some.
-grab a rubber mallet and start pounding around the edge where it seats against the transmission. Occasionally try to wiggle it, eventually it will get loose enough and you can remove the couple bolts you still have in and it should come right off.
You can use a flat head to try to pry it, but I would be super careful and wrap a rag around the head as to not gouge out the surface on the tcase or transmission. The transfer case can be a pita. Reason I left a couple bolts in, I didn't want it falling on my face or on the ground!
Like this:
Last edited by RoninVIIIRS; Dec 5, 2010 at 09:08 PM.
thread a bolt into the output shaft? Hmm not sure. I tried to follow the instructions on evomoto and evolutionm. Can you tell me alittle more about the bolt? Right now i removed all 6 bolts on the Transfer case and i was about to pull it apart from the transmission itself about an inch but it wont go any further then that. I even removed the whole umm output shaft behind the transfer case? The big black pole. So its just the transfer case itself thats not coming out..
http://www.evomoto.com/tech_articles..._article_id=27
step 28
&& did you get the one bolt behind the banjo bolt on the top?
step 28
&& did you get the one bolt behind the banjo bolt on the top?
The banjo bolt wont, but there's a bolt that can be a PITA to get out without removing that banjo bolt. I got a good picture of it years ago, let me see if I can find it again.
If you're separating it, then you've likely already got it loose
My guess is axle stub.
If you're separating it, then you've likely already got it loose
My guess is axle stub.
Last edited by Brian; Dec 6, 2010 at 05:25 AM.
My bad, forgot about the stub shaft that has to be removed. You pull it from the driverside, use a slide hammer and a 10 or 12mm bolt. Thread the bolt in a bit, attach slide hammer, and give it a pop. Comes out real easy.
EvoM to the rescue! Obtaining this kind of help or knowledge on other car forums is almost impossible. Every time I venture to another car sight it's disappointing...must be because they are german cars and nobody does there own work on them 
I had a Corrado once. I'm pretty sure the manual called for the engine to be removed to replace the water pump. I found that by taking off the front engine mount, and jacking it up 2", you could access it lol.
Thanks guys for all your input and help! I finally got the transfer case off after three hours. Taking that output shaft out was a pita. Had to come up with my own rig to pull it out since I didn't use the method listed on the diy.
