Removed my QuadraTrac and fuel tank

[NO6YHY]

Its real easy to damage the seals or knock them out of square when pulling or installing the transfer case, is the output shaft grooved where the seal rides? did you replace the bearings in the case?, is the output shaft bent slightly? I "bench press" the transfer case in and out as I have better control as it goes in. and can keep it square. just some things to think about...

Yep, I "bench press" it too. Usually takes a few seconds to find the hole. But in the few times I've had it out, the seals were always in place and looked good. Did not check whether output shaft was grooved. I also don't recall replacing bearings, or where those bearings are located in the case.

If all fluid is kept in by the seals, what is the function of the gasket between transmission and t-case? Does any fluid come out of the transmission?

Anyone have thoughts on whether putting two gaskets there would be ok?

[bkilby]

Get some long bolts and cut the heads off to use as guide pins. I believe you want 7/16-14 by 4" long. The FSM will confirm.

Does anyone have any tips or experiences to share with me? I need to create a jig to properly level the transfer case and jack it back up into position and reattach it to the transmission. I'm a one person show and there are no extra hands to assist.

[Driftwood]

After installing the fuel tank, I noticed I may need to remove it to allow for the installation of the Borg Warner transfer case. The front end of the tank doesn't seem to allow much clearance for installation of the BW.

Can anyone with transfer case installation experience share their advice?

It wont be to terribly difficult to drop the tank. None of the fuel lines are connected and the tank is only loosely installed with 3 bolts.


Here some ramblings below.

Sealed the fuel tank with J-B Weld SteelStik. New Sending unit, new pick up tube, all new fuel lines. There were many.

1"
3/4"
5/16"
1/4"
3/16"

Installed the tank this morning with the three bolts, 2 on the front, 1 on the rear.

Haven't installed the crossover strap yet. It is secured in place with 5/16 bolts and 11/16 nuts.

The J-B weld patch can be seen in the below pic near the RH end of the tank.

[Driftwood]

I also did some patch work on the Heater core box. A couple holes needed attention. Also removed about 2 lbs of leaves.

[babywag]

It can be very tight, if tank is easy to remove go ahead and do it. It'll make job easier vs. fighting around it/lack of space.

I've done it all too many times w/ tank still in, sucky job.

Be sure to use guide bolts/threaded rod cut length etc. to reinstall case.
Don't nick/scratch/look @ those QT seals wrong, or very high probability it'll leak.

[Driftwood]

I figured the space would be limited. I'll drop the tank.

I'll remember to look at the Borg lovingly and whisper sweet nothings to it to prevent seal damage during installation.

I'm doing all this work on my back with the wag up on jack stands. This will add to the stress of maneuvering the "heavy as hog" borg.

I'll buy a transmission jack to lift the Borg into place.

I want to install the Borg with the low range unit installed and all fluids topped off.

Thoughts?

It can be very tight, if tank is easy to remove go ahead and do it. It'll make job easier vs. fighting around it/lack of space.

I've done it all too many times w/ tank still in, sucky job.

Be sure to use guide bolts/threaded rod cut length etc. to reinstall case.
Don't nick/scratch/look @ those QT seals wrong, or very high probability it'll leak.

[Driftwood]

Any thoughts on reinstalling the Borg with the front drive line attached?

I removed the Borg with the line attached because the driveline hardware was impossible to reach for removal.

[rang-a-stang]

Any thoughts on reinstalling the Borg with the front drive line attached?

I removed the Borg with the line attached because the driveline hardware was impossible to reach for removal.

that's how I did it...

[Driftwood]

that's how I did it...

So tell me about the reinstallation

[PlasticBoob]

Piggybacking on this thread, does anyone know if it is alright to put two gaskets between the t-case and the transmission? I have had this thing off and on three times and can never seem to get rid of a little leak right there. I think the mating surfaces aren't entirely true. Will putting two gaskets in throw off anything critical?

This is extremely common, but don't put two gaskets together. Use one of the gaskets and trace it onto 1/32" custom gasket paper. Cut it out and there's your new, thicker, custom gasket. You will reduce, or in my case, completely eliminate that leak you're talking about.

[PlasticBoob]

Any thoughts on reinstalling the Borg with the front drive line attached?

I removed the Borg with the line attached because the driveline hardware was impossible to reach for removal.

I remove and install the transfer case without the front driveshaft installed.

First, make sure the rear driveshaft is installed, and then mark the position of the joint and yoke with white paint/chalk/etc.

When loosening the bolts that hold the double-cardan joint to the transfer case front output yoke, I will push the Jeep forward or rearward in order to rotate them into an easier position to get a wrench on the head. Assuming you have a few feet to play with, and are not on a slope, it's easy. Installation is the reverse of removal.

In your case, if you're having difficultly reinstalling it with the front driveshaft attached, I would simply remove the shaft and reinstall it using the above procedure once you have the transfer case in and the rear driveshaft back on. Let us know how everything goes!

[PlasticBoob]

By the way, I would highly recommend replacing the double-cardan joint if you aren't sure when it was last replaced or greased. I have personally seen one split an entire TH400 in half and destroy a QuadraTrac when it let loose on the freeway.

[rang-a-stang]

I pushed the front drive shaft up and over the crossmember, bolted the Xfer case to the trans adapter, then assembled the front drive shaft to the front pinion. Last thing for me was bolting the reduction gear assembly on, speedo cable, etc.

I have a part time kit installed. Not sure if that makes a difference....

[Driftwood]

I pushed the front drive shaft up and over the crossmember, bolted the Xfer case to the trans adapter, then assembled the front drive shaft to the front pinion. Last thing for me was bolting the reduction gear assembly on, speedo cable, etc.

I have a part time kit installed. Not sure if that makes a difference....

I may attempt your procedure first. If it's a no-go, then I'll follow Robs instructions.

[Driftwood]

I am making a pattern for a glove box . Many years go I had done this for my 85 wag. I have since lost the pattern. The aluminum glove box I created conveyed with the 85. It was sold in 1996. I found this old cardboard glove box in a junk yard. I carefully pulled the super strong staples apart and soaked the entire box in water and laid it out flat. After it is dry, I will make a pattern of it. It won't be a perfect pattern. Some of the box's corners are in poor shape.