2-Big Broncos 4x4 Technical White Papers

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Automatic Hubs/Transfercase Conversion

Well the T-case itself cost me $400 with exchange of the old one.  Thee
shifter was about $30, and the Warn hubs were $80.
The installation was pretty easy, though I must admit I was sorta
nervous about it before hand.
1.  Drain the fluid from the electronic case and disconnect the wiring
harness at the shift motor.  Then disconnect both drive shafts from the
t-case.
2.  Put a jack underneath the t-case to support it and begin to unbolt the
case.  I believe they are either 1/2" or 13mm bolts, you will need a
flex-joint socket to get the upper bolts off as the is not enough clearance
between the body and the t-case housing.
3.  Once the case is unbolted you can go ahead and slide it off the output
shaft of the tranny.  The case is not very heavy (I'd say about 70lbs.) so
one person and a jack or two people can lower it quite easily.
4.  There is a gasket that sits between the tranny and the t-case so you're
probably going to want to replace it at this time.  Once t