2003 Dodge 3500 Transfer Case Replacement

BoRo · 01-13-2009, 04:21 AM

The transfer case in my truck needs to be replaced. My dealer quoted me a labor cost of $900 plus materials. I found a reman. transfer case for around $700. My question is what is involved in replacing the transfer case? Can someone point my to a site that gives replacement instructions? Degree of difficulty involved?

foxdodgeman1998 · 01-13-2009, 01:58 PM

is this a cummins because if so or even if not you can try <removed link> and they might be able to help all you have to do is make a profile. i have been on there and they were very helpful.

stumpuller454 · 01-13-2009, 10:11 PM

peace of pie, hardest part is breaking loose the bolts holding it on, i don`t recall even having to remove any crossmembers...

terrywerm · 02-17-2009, 02:21 PM

Replacing the transfer case is a piece of cake. Keep in mind that these instructions are from memory and are rather generic. Be sure to firmly block your wheels before starting so that the vehicle does not move once you disconnect the drive shafts. For safety's sake DO NOT rely on your parking brake. It is not necessary to raise the vehicle up on jackstands, but some people prefer to raise the vehicle up a few inches anyway. Doing so does give a little more room to work.
1. Remove the skid plate from under the transfer case.
2. Drain the oil from the transfer case.
3. Drop the front driveshaft by unbolting the driveshaft flange at the front of the transfer case.
4. Remove the rear driveshaft at the rear axle by removing the u-bolts that hold the u-joint.
5. Pull the rear driveshaft out of the rear of the xfer case.
6. Disconnect the vehicle speed sensor wires (left rear of transfer case)
7. Disconnect the vacuum lines for the Central Axle Disconnect (CAD) - they are located near the front of the transfer case, up on top.
8. Disconnect the shift linkage for the transfer case.
9. Support the transfer case with a transmission jack.
10. Remove the bolts that mount the transfer case to the rear of the transmission.
11. Work the transfer case loose by working it rearward. Once it is loose, drop it down and remove it from under the vehicle.

Installation is just the reverse order of the steps listed above.

Terry

01-13-2009, 04:21 AM	#1
BoRo Junior Member Join Date: Jan 2009 Posts: 1	2003 Dodge 3500 Transfer Case Replacement The transfer case in my truck needs to be replaced. My dealer quoted me a labor cost of $900 plus materials. I found a reman. transfer case for around $700. My question is what is involved in replacing the transfer case? Can someone point my to a site that gives replacement instructions? Degree of difficulty involved?

01-13-2009, 01:58 PM	#2
foxdodgeman1998 Full Member Join Date: Jul 2008 Posts: 23	is this a cummins because if so or even if not you can try <removed link> and they might be able to help all you have to do is make a profile. i have been on there and they were very helpful. Last edited by bradrhale; 01-13-2009 at 03:16 PM. Reason: no advertising other forums on open forum

01-13-2009, 10:11 PM	#3
stumpuller454 Senior Member Join Date: Dec 2007 Location: Grande Prairie, AB Posts: 2,043	peace of pie, hardest part is breaking loose the bolts holding it on, i don`t recall even having to remove any crossmembers... __________________ SUPERCHARGED 454 K2500 GMC! 450hp and 600ft/lbs http://www.youtube.com/watch?v=WJ27RJHfJKE "sailing with Captain Morgan often!"

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02-17-2009, 02:21 PM	#4
terrywerm Junior Member Join Date: Feb 2009 Location: Jordan, MN Posts: 6	Replacing the transfer case is a piece of cake. Keep in mind that these instructions are from memory and are rather generic. Be sure to firmly block your wheels before starting so that the vehicle does not move once you disconnect the drive shafts. For safety's sake DO NOT rely on your parking brake. It is not necessary to raise the vehicle up on jackstands, but some people prefer to raise the vehicle up a few inches anyway. Doing so does give a little more room to work. 1. Remove the skid plate from under the transfer case. 2. Drain the oil from the transfer case. 3. Drop the front driveshaft by unbolting the driveshaft flange at the front of the transfer case. 4. Remove the rear driveshaft at the rear axle by removing the u-bolts that hold the u-joint. 5. Pull the rear driveshaft out of the rear of the xfer case. 6. Disconnect the vehicle speed sensor wires (left rear of transfer case) 7. Disconnect the vacuum lines for the Central Axle Disconnect (CAD) - they are located near the front of the transfer case, up on top. 8. Disconnect the shift linkage for the transfer case. 9. Support the transfer case with a transmission jack. 10. Remove the bolts that mount the transfer case to the rear of the transmission. 11. Work the transfer case loose by working it rearward. Once it is loose, drop it down and remove it from under the vehicle. Installation is just the reverse order of the steps listed above. Terry