Well, I finally tackled this project. To be honest, I'm a novice shade tree mechanic at best, and initially felt this was above my ability. I purchased a new actuator a year or so ago, trying to work up the courage to do it myself, or suckup the cost and have it done for me. I contacted two well known transmission shops in town, and neither would take the job. They saw what was involved, and said no thanks. Didn't even give me some ridiculously high quote--just no. The local dealership wanted $1,650 in labor alone. With the Coronapocolypse giving me a bunch of unexpected time at home, I figured it's now or never.
The initial write up is great, and I appreciate the OP, and every one else who added some advice along the way. I didn't have the leaking problem that others have had. My issue was that the actuator wouldn't operate the CDL at all, and would operate the low range inconsistently. I bought the Asin actuator from ebay--I think it was right at $500. I also bought 3 new shift rod c-clips, just in case i lost or damaged them. I meant to buy a new actuator breather hose, as mine was cracked (and quite possibly the ultimate cause of my issue) but I forgot. However the auto parts store had the correct size hose, so I made my own.
I managed to borrow a scissor transmission jack, which was worth it's weight in gold. Like some other posters here, I fabricated a jig to hold the t-case level on top of the jack. This made reinstalling much easier. If anyone is planning on doing this job and wants my jig, it's yours for free (but it's just scrap lumber that anyone could make). One thing I can add is when you get to the point of splitting the case, look at the top side, just above the front driveshaft output--there is a feature on the case designed for some kind of special tool to 'screw' the case apart. I just used a long bolt with a nut, tightened the bolt, and presto--the case splits right in half.
I wont lie--every step of the way I felt i was in over my head. But the OP is well written, and covers everything. Have the right tools on hand, follow the OP and take your time. I would estimate it took me right at 12 hours, and I wasn't in a hurry (and I changed the oil as long as I was under there).
The initial write up is great, and I appreciate the OP, and every one else who added some advice along the way. I didn't have the leaking problem that others have had. My issue was that the actuator wouldn't operate the CDL at all, and would operate the low range inconsistently. I bought the Asin actuator from ebay--I think it was right at $500. I also bought 3 new shift rod c-clips, just in case i lost or damaged them. I meant to buy a new actuator breather hose, as mine was cracked (and quite possibly the ultimate cause of my issue) but I forgot. However the auto parts store had the correct size hose, so I made my own.
I managed to borrow a scissor transmission jack, which was worth it's weight in gold. Like some other posters here, I fabricated a jig to hold the t-case level on top of the jack. This made reinstalling much easier. If anyone is planning on doing this job and wants my jig, it's yours for free (but it's just scrap lumber that anyone could make). One thing I can add is when you get to the point of splitting the case, look at the top side, just above the front driveshaft output--there is a feature on the case designed for some kind of special tool to 'screw' the case apart. I just used a long bolt with a nut, tightened the bolt, and presto--the case splits right in half.
I wont lie--every step of the way I felt i was in over my head. But the OP is well written, and covers everything. Have the right tools on hand, follow the OP and take your time. I would estimate it took me right at 12 hours, and I wasn't in a hurry (and I changed the oil as long as I was under there).
