Ralph241

Hi,
I have a big problem. My transmission has died so I bought a rebuilt one and am attempting to install it. First I tried to take the transfer case off of the transmission and pull the transmission that way. There just isn't enough room so I put the transfer case back onto the transmission and pull the entire assembly. Once again I ran into the same thing. Do I need to lift the engine to remove this thing? I have just about killed myself trying to get this thing out.
PLEASE is someone knows what I am doing wrong let me know.
I am at the end of my rope.
Thanks for any and all help,
Ralph241

MT-2500

If you do not have some real good stands and transmission jack it is best to pull transfer case and then the transmission.

Transfer case has to be twisted/turned just right to come out.
Good luck

__________________
Remember proper testing gives us the answer to many problems.
MT

MT-2500

http://72.19.213.157/files/4L60ERemoval.html

http://72.19.213.157/files/4L60ERepairs.html

__________________
Remember proper testing gives us the answer to many problems.
MT

Ralph241

Thanks MT 2500.
The links are dead though.
Please resend them if you could.
Thanks for the help.
Ralph241

MT-2500

Sorry about that.
Give Blue Bowtie a pm maybe he still has it some place.
Or a all data oline info sub.will have it in detail.
http://www.alldata.com/products/diy/index.html

Also most public libary's have good car repair info.
And AZ web site has some.

__________________
Remember proper testing gives us the answer to many problems.
MT

Ralph241

I did get the subscription to all data and it was useless.
Has no details that I could find. I also went to Chiltons diy site. wasted about 50 bucks on subscriptions yesterday.
I do appreciate you help MT2500.
I might take a day off and heal up some before going back at that thing.
Happy Fathers day to everyone.
Ralph241

MT-2500

\

It real easy to remove transmission and transfer case together.
Or can be done by pulling transfer case first.
Which ever works best for you.
Just get everything un hooked and off of transmission and transfer case.

Slide it back as far as you can and with cross over pipe off and converter hold in tool on it lower front of transmission down below engine and pull it out forward.

A good transmission jack that will raise and lower and tilt it way down in front is a almost have to have.

Also have truck up high enough on on good stands.
There is no reason why all data does not cover it.
All Data is almost a copy of the factory manual.
The info should be in the all data sub
Find transmission removal in it and or transfer case removal..
If you can not find it all data has great support on stuff.
If not in all data they will get it and fax it to you.
Call or e mail them your problem.
What did you find on transmission removal or transfer case removal?
Post back what you found or where you looked in it or what it said.
Good Luck

__________________
Remember proper testing gives us the answer to many problems.
MT

Ralph241

Hello again.
I looked under the Vehicle » Transmission and Drivetrain » Transfer Case section as well as the Vehicle » Transmission and Drivetrain » Automatic Transmission/Transaxle » Service and Repair » 4L60-E » Transmission Replacement section. There is no place that I can see that discusses the removal of the torsion bar cross member.
I attempted to make a tool to compress the torsion bar tensioners but it didn't work out very well. I ordered the proper torsion bar unloading tool. Should be a snap after the cross member it removed.
Thanks for all the help , I do appreciate it.
Ralph241

MT-2500

That is because you do not do that way.
What did trhe remove and install section say to do?

You do not remove the torson bars or torson bar cross member.

Just remove the crossmember under back of transfer case.
And drop down/off the exhaust cross over pipe.

If pulling tramsmission and transfer case together.
You slide them back to torson bars crossmember and lower front of transmission way down below engine flywheel and go forward with them.

It takes a good transmission jack to pull them that way or all together.
Good Luck

__________________
Remember proper testing gives us the answer to many problems.
MT

Ralph241

I just email them for further instructions. This is turning into a real nightmare for me. We tried to take the transfer case out and it is hanging up on the output shaft of the transmission. We tried to take the whole assembly out and it hangs up on the flywheel bolts.
I am totally lost. I have been working on cars most of my life and this thing is killing me.
Thanks,
Ralph241

MT-2500

The trick is to twist it around just right.
It will come out either way.
Let us know what all data support does/or says.

They have always been very helpfull for me.
Good Luck

__________________
Remember proper testing gives us the answer to many problems.
MT

j cAT

this transmission is about 175lbs...with the transfercase over 200lbs..

you will need another person to aid in the removal..and the vehicle will need be off the ground a very good amount so that it will exit to the front of the vehicle..

slide the transmission/transfercase toward the rear then when its clear of the engine drop the forward part of transmission and move the unit fwd toward the front of the vehicle...

best if done on solid concrete floor smooth...and level....

if you don't have the proper equiptment you should have a shop drop/install....

Ralph241

I GOT THAT BAD BOY OUT!!!!!
Had to stop and look at what I was doing wrong. Put the transmission back onto the engine and looked stuff over. What I was doing wrong was this.
The part that goes between the transmission and transfer case was the hang up. I took it apart with the part that the cross member bolts to still attached to the transfer case. After taking the nuts off and leaving the cross member mount attached to the transmission the transfer case then had enough room to pull back and twist it out. The rest was easy after that. Can't believe it was that easy. Next time (hope there isn't one) it will be easy.
I really appreciate all the help from you guys.
I owe you all a beer or two.
Thanks once again,
Ralph241

MT-2500

You are welcome and thanks for posting back how it went.

__________________
Remember proper testing gives us the answer to many problems.
MT

Ralph241

You are NOT going to believe this.
Got everything in ans went to put the torque converter inspection cover on. It will not work. The rebuilt transmission has no holes in it for a dust cover. The transmission guy wants me to pull it back out and swap bell housings. Is there any way that I can find the proper cover for this thing???? The bell housing part number or casting number is 24200877.
Thanks,
Ralph241