I can't get front drive shaft to push back into transfer case.

[exp500]

Cutoff wheel would be a sure thing, sawzall maybe, depends exactly where you cut. Yoke has a case hardened surface,once thru that sawzall no problem.
Yes you must replace front driveshaft Yoke. Recommend a Upullit- TCase and driveshaft. Also save switching box on side of tcase. Also SAVE your front D/S BOOT. No longer available seperately. Getting one from Upullit you can get all the plastic clips Harness attachments, vent line elbow and other hardware tough to find.
Recommend you split trans/tcase before you get parts- to decide if trans rear seal leaking.Trans fluid should not mix with tcase- failed tcase failed trans if leaking. Otherwise get trans from upullit too. If I remember right, the ujoints on front driveshaft are 3147's so cheap to fix rather than $300 for rebuilt.
With the front driveshaft yoke frozen to splines, Brother should have had noise/vibration in 4x4,especially on bumps when front suspension moves. Lube Splines on install. Make sure they are clean.

 

[chicagochuck]

Yes, I'll get the front splined yoke from the junk yard.

I'll let you know if I can get the T case out with front yoke attached, once i get the U joint out. I'm going to rent a ball joint/u joint press tomorrow. I am hoping I have enough clearance, do bring it down.

How do you know or whats the procedure to test if a junk yard T case is any good besides checking the the fluid and turning by hand checking for play in the yoke? And your procedure for testing a junk yard Trans?

According to Dash code NP8 I have the NP246 transfer case. So I have an idea what to look for... 98-2000...

Thanks

 

[Fless]

According to Dash code NP8 I have the NP246 transfer case. So I have an idea what to look for... 98-2000...

Expand your search; my '04 has the 246 also. Many of these trucks have the Auto T/C.

Now that I said that, you'll want to check the spline count on the shafts, it seems that there may have been a difference over the years. Also, the little shift shaft that the encoder motor turns, some have two flats on them and later ones have multiple splines.

 

[exp500]

Fless- good call, Spline count matters on output shaft too.
Take pictures of everything, really helps when you need it. Easier to count spines on a pic than layin on your back gettin dirt in your eyes.

 

[chicagochuck]

Update: I did get the T case out on Sunday. I ended up cutting the u joint. A guy a few miles from me has a T case from a 1999 Tahoe. But does not have the car anymore. He scraps a lot of cars. So he doesn't know if it had 4 button switch. It still has the yoke and front drive shaft attached.

The spline count is the same and its a NP246, with same gears as mine. But My T case has a blue Auto trak fluid sticker, his has yellow Dexron sticker, so I am not sure, it that means it wouldn't work.

 

[exp500]

Look in your glove compartment for the RPO codes. Run the numbers thru decoder or list. Determine if your electrics are Auto Trac. Which dash switch helps too.

 

[chicagochuck]

Thanks.

Will do