My transfer case is leaking badly and wants to pop out of 2 high when I let off the gas. First off, has anyone else experienced the same problem with it jumping out of gear? Second, is it hard to remove the transfer case from the truck? I plan to replace all the bearings and seals while it is out of the truck.

The Dana 20 is Heavy!! I eventually had to pull the motor out and put everything back in from the front. I'm sure there is an easier way, there has too be!!! There are 12 roller bearings that the output shaft of the tranny ride on, they will fall all over when you disconnect the t-case from the tranny, you may want to pull the tranny and t-case out together then the bearings will be easier too find!! It's not a difficult thing, just alot of heavy lifting and manuvering, buy some beer and invite a couple buddies over, or rent a transmission jack!<br>Good luck,<br>Jeff<br><a href=http://www.broncoadventures.homestead.com target=new>http://www.broncoadventures.homestead.com</a>

My old transfer case was popping out of low range when I let off the gas. I figured that it was due to worn gears. I ended up just buying a rebuilt one from Jeff's. Not cheap but worked out just fine. I have pulled the t-case enough to want to use wings nuts on it. The tough part is getting at some of the bolts. The ones on the top are the worst. A crow's foot helps. It is heavy to lift down but do'able, especially with help. Don't try to 'bench press' it if you are not sure. In my experience the jack shaft (input to the t-case), bearings, and retainer have stayed in the t-case. I would drain the oil out it.

Bronco408w,<br>Thanks for the info. Where you able to get the t-case out from the bottom without removing the engine and transmision? In my case they also need rebuilt, sounds like I might be farther ahead to wait and pull the entire drivetrain. Did you have to remove the seats and floor covering to get better access? I'm building a 302 w/ 289 heads to replace the existing motor. I'm also planning to rebuild the tranny. I may just keep adding oil for now and hold on to the t-case shift lever to keep it from popping out.<br>Thanks again,<br>Gman44310

No problem on the info. I have pulled the t-case while leaving the engine and trans in place several times. About pulling the motor and trans, I guess it all depends on how much you plan to do at one time. I have a fiber glass body so things might be a little different, clearance wise. There are 6 bolts that hold the t-case to the adapter housing. I can get 4 of them from under neath. The other 2, I get thru thru the hole for the t-case shifter. Almost forgot, if you pull just the t-case, you should drain down the trans. The rear seal on trans and the front seal on the t-case are the same. I dropped about 4 quarts of ATF on my garage floor; what a mess. Also, the t-case shifter needs to come off. <br>Good Luck