Having done the job, I just don't see how that would be possible.

The chain needs to be wrapped around the sprocket inside the TC, so you basically have to assemble everything at once.

MAYBE, if you got the bottom of the TC off (I forget if that is possible without removing it), and you had one of those chain tools (connects and disconnects the chain at the link, forget the name), then you could feed the new chain up and around the sprocket, and reconnect it.

Easier to drop the TC....

I thought it might be a little different with a 3.0. Thanks for the info.

I don't think this is possible, the chains are manufactured to size without a master link. All the pivot pins are mushroomed at the endplates if I'm not mistaken.

I was able to replace the chain without removing the tc. 3.0 might be a little different with a 4.4 bec the exhaust pipes were not in the way.

Care to elaborate? How did you handle getting the chain around both sprockets?

Sorry if I've missed it, Where do you purchase the chain from?
Also, are the other TC parts available?
I live in Australia and can't seem to find anything local. all the US prices you guys mention are 50% more on this side of the Pacific.

You buy all the parts from here: Automatic, Standard Transmission and Transfer Case Rebuild Kits, Cobra Transmission Parts 1-800-293-1848, Cobra Transmission

Thanks
 

Just finished this job and was not to bad. Started with wrenchs and such but really requires a good impact. Made the job easy. Thanks for the post, i would not have attempted without. I used 18v dewalt impact, cobra chain and all else was able to use again. Total repair bill $107.00 plus my time approx 8 hours total. Thanks again great work

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