2003 Silverado 2500HD ext cab long bed 4x4

My transfer case has to come out, so I was working on it last night. I got all the nuts taken off the studs that would seperate the TC from the trans, but I cannot figure out how to physically get the TC OUT of the truck. Do I need to take out the torsion bar crossmember? The crossmember sits 2" from the tail of the transfer case (2" of the transfer case extend PAST the crossmember), right on top of it.

If so, how do I go about SAFELY removing the torsion bars, crossmember, and how do I go about putting it back up after I put the transfer case up?

 

If you are not pulling the trans. you will need to pull the crossmember out,I think kysilverado did good writeup of how to remove it in his 4L60-4L80 swap thread with lots of pics.I would look there!

 

It will come out of the 1500 series without removing the torsion bar cross member. You have to slide it back far enough to get it off the studs and angle it down from there. Doing it this way, without removing the cross memeber, make it more difficult to do without damaging gasket and gasket surface from the studs scraping across them.

 

So it would be beneficial to just remove the torsion bar cross member? From your post it seems like it would be safer that way. It doesnt seem like I have enough room to slide it back and tilt it down before it would start hitting on the transmission.

 

you have to jack stands under the frame high enough that tires r off the ground then put good marks on torsion bars where they or @ to make sure u put them back in same place! get a good heavy duty C-clamp theirs a dip in the torsion keys on the side of the bolt where u adjust the height place C-clamp there to hold tenion & remove bolt & back off on c-champ till torison bar comes lose! side torison forward & remove key! hope this helps

 

If I were doing just the transfer case I wouldn't remove the torsion bars. Just be careful and an extra hand or two helps.

 

Slide it back, turn it sideways, drop it down. Very easy, not necessary to remove crossmember.

 

good deal, I will try it tomorrow then. Thanks guys.