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06:51:52 - 04/26/2024
Raised / Lifted Dakotas
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T-4 Mike
Dodge Dakota
JOIN HERE
6/23/2007
14:19:15
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 Subject: transfer case
IP: Logged
Message:
I have a 1994 Dakota that I need to change the transfer case in. I am hoping somebody on here can put something on paper so I can follow it step by step. I am mechanically inclined but being papralyzed from the chest down makes it a little hard to reach some areas.
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Moser
Dodge Dakota
JOIN HERE
6/30/2007
00:40:59
|  RE: transfer case
IP: Logged
Message:
Jack up front of truck and support with stands beneath flat part of frame behind front tires, making sure front tires are off ground.
Jack up rear differential and support axle with stands ensuring rear wheels are off ground.
Put transfer case in neutral and remove transfer case shift knob.
Drain transfer case.
Remove 5/16" bolts securing rear drive shaft U joint to rear differential yoke. Should be able to spin drive shaft to reach each bolt.
Do same as above to front drive shaft at transfer case. Push drive shaft aside or remove 5/16" bolts securing front of drive shaft to front differential yoke.
Remove transfer case shift linkage and shift rod from left side of tranny.
Disconnect the electrical connector on the left rear of the transfer case and unscrew the "speedo cable" right beside the connector and pull it out if there is one. The cable is not actually for the speedometer but is like a speedometer cable.
Unscrew all 6 nuts that hold the transfer case to the tranny. The top 2 are a real pain. I get the top left by going through the cut out in the floor for the shifter. So removal of the shifter bezal inside would be neccassary. All 6 studs are tight up against the transfer case so you can't easily use a ratchet and socket. I used a 9/16" box end wrench doubled up with another wrench to break them free and then a ratcheting wrench to finish them off. The top right was real tough because it is real close to the floor. I have a 2" body lift and I still had trouble. When pulling the transfer case back to separate it from the tranny be real careful, it is very heavy and akward when you're lying on your back. My shoulder stopped it from crashing to the ground (Ouch!).
When I replaced my transfer case, I also changed the rear output shaft seal of the tranny, the slip yoke seal and bushing on the back of the transfer case while I had everything apart.
Installation is pretty much just a reversal of the above.
I hope I did not leave out anything important. My Dakota was a '92 so I had a couple of vacuum lines to deal with, but I think that's all that is different. My truck was also a short wheelbase truck so extended cab trucks may have a cross member in a different location or maybe even a longer rear driveshaft with a "hanger bearing". Remember to fill the new transfer case with ATF until it comes out the fill hole. Good luck!
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