Gearbox installation with or without transfer case on an M38

Herrmann_Sherman · Post by **Herrmann_Sherman** » Sun Nov 09, 2014 4:17 pm

I´ve removed my T90 transmission (complete). It was not as easy as I thought and I had a lot of work with it. Now I´m thinking about (after cleaning etc.) reassemble. Is it much more easier to assemble at first the gearbox and in an extra step the transfer case with handbrake or should I assemble both together?
Need your opinon, meanwhile I have a pulley...is it necessary to remove all of the covering (metal sheet) in the Jeep? Please note that I don´t have any assistants

Regards
HS

hillbilly21 · Post by **hillbilly21** » Sun Nov 09, 2014 5:23 pm

PERSONAL PREFERENCE ON MY END IS DO BOTH AT THE SAME TIME..
REMOVE ALL FLOOR PANS MAKES ALOT MORE ROOM ...GOOD LUCK

BBDE · Post by **BBDE** » Mon Nov 10, 2014 3:12 am

Install both together.
It will be very tricky to install the transfer after the gearbox is installed .
It is much more easier to install the gasket in between, when you do this outside the vehicle.
Note, the transfer will become also a heavy after some time of handling when you laying under your vehicle. To place the screws and the gasket in this situation is not so easy.

And yes, you have to remove the "covering"

Frank

skyjeep50 · Post by **skyjeep50** » Mon Nov 10, 2014 7:54 am

My preference has been to remove the engine, trans and all accessories as a unit. The M38 and M38A1 was designed for the power plant to be pulled all together, all accessories and the radiator included. All you need is a engine hoist. Then you can work on components at bench top height, disassemble and assemble as needed and then reinstall the entire power plant as a unit. Yes, you have to pull the floor panels but that isn't that big a job, just takes a little time. Pulling the power unit takes about an hour for one person. Putting it back takes a little little longer but very little of the work is crawling around under the jeep.

45auto · Post by **45auto** » Mon Nov 10, 2014 10:06 am

I agree with pulling and installing as a unit, however, I have installed and pulled just the transfer in a CJ2A, 3A ect. I used two 4 inch long 3/8, grade 8 bolts with the heads cut off and with the ends rounded, installed in the top bolt hole locations in the transmission. If you are taking the transfer out, you have control of it as you slide it of the modified bolts and when re-installing, you can have the gasket installed, line up the transfer on the two bolts and slide the transfer back on. Complete installation from there. Since your M38 has removable floor pans, remove them and take advantage of the room and space it gives you. With this method, I found it easier to handle, line up and install the transmission and then install the transfer.

Do note, I am assuming you have the knowledge of what all needs to be taken off, proper handling of a heavy transmission and transfer and you have proper transmission jacks for your use. If not, buy or rent the proper equipment and/or get someone to help you!! While not all that "heavy" outside the jeep, they are very heavy when you are under them!! Think ahead--and be safe!!

Herrmann_Sherman · Post by **Herrmann_Sherman** » Mon Nov 10, 2014 11:41 am

Many thanks for your ideas.

I´ve taken both of them out and used myself as a Jack...I was under the transfers and was lifting with my arms to get it out

My idea is now to remove the covering for more space and to use the pulley for to bring BOTH on the right place...I will put them together bevore installing (Gearbox and transfer like Frank said )

Post by **wesk** » Mon Nov 10, 2014 12:11 pm

Once you have the weight attached to your hoist (pulley) it becomes a much easier job under the jeep.

I hope you performed a thorough inspection of the transfer case while it was removed and repaired any issues already? Key areas are the shifter stalks and the output drive flanges. If the shifters are sloppy (loose) and if there is any evidence of gear oil leaks at the drive flanges this is the time to fix them.

Herrmann_Sherman · Post by **Herrmann_Sherman** » Sun Nov 16, 2014 10:09 am

Another question is:
Is it easy to remove the shift levers and replace them after the transmission is back on place? This would help me a lot...

Post by **wesk** » Sun Nov 16, 2014 11:03 am

With the three floor panels removed it is easy.

4x4M38 · Post by **4x4M38** » Mon Nov 17, 2014 12:20 pm

Related question.

My M38 has a weird looking, off white, flat top shifter knob.

The transfer case knobs are round and black.
They unscrew pretty easily. The other one does not.

Is it safe to assume the shifter knob is threaded on as well?

If so, I'll "work" on it some more.

Tks,
Brian

Post by **wesk** » Mon Nov 17, 2014 5:51 pm

No. Some shifter knobs are press on. Depends on what the tranny came out of.

Gearbox installation with or without transfer case on an M38

Gearbox installation with or without transfer case on an M38

TRANNY