Separating Transfer Case

Fellers - In order to get to my NP trans, as you probably know, the transfer case has to come down.  Everything's disconnected 'cept where the case meets the cast iron mating tunnel (?).  Sounds romantic!

Anyway, should this baby just slip out with a little more persuasion?  I don't want to break things...but it's not just sliding out like a typical splined shaft would.  Thanks!!

Sorry...here's a better view.

There shouldn't be anything other than a splined shaft, Tom.
Maybe a locating dowel has corroded?

Perhaps moisture has gotten in there over the years and rusted them together?

You might try a ratchet strap connected to the rear in order to put in-line tension on it while you work to break the grip.

Definitely use moly paste or anti-sieze on the splines when it goes back together.

Thank you, Jim!!

Definitely will re-lube.  

What model transfer case do you have. BW 1345?

I believe it's the 208.

Now down to the cross member and NP435.  I know that thing weighs a ton and I have the jack & chain in place.  Going to re-read the steps involved in the Documentation section before loosening any bolts.  

The crossmember is going to be a bear because of rusty and/or painted fasteners - also hard to get an impact wrench in the tight spots.

Can I remove this cast iron adapter tunnel before removing the trans?  I've removed the two bolts holding it to the crossmember.



Also, I'm thinking I need to support the bell housing once I remove the NP435 otherwise the engine motor mounts will be severely stressed from the lack of rear support.