1978 fj40 transfer case removal, how to?

[owlridge]

I am trying to remove my transfer case from my transmissin and have removed all mounting bolts but can not release from shaft. I have 2 crow bars trying to slowly pry but no moment yet.

is there a special puller?

do I need to remove the bearing type cup? attached in pic

will it destroy the bearing if I need to remove it incase its tapered?

I can wiggle the transfer case but it doesnt want to budge, I can spin the entire transer case around so I am sure all mounting bolts r removed.

is there a trick to this?

 

[inkpot]

Howdy! Most likely the splines on the output shaft have a lot of wear and the input gear is having trouble going from the worn section to the virgin area towards the rear. Imagine railroad tracks that are suddenly off center by 1/4 of a rail. Only way to do it is just keep adding force till it slides over. I made a puller out of angle iron, with two long bolts screwed into the case on either end, and a center bolt to fit into the indent on the ind of the output shaft. Worked for me. John

 

[owlridge]

bearing

does the bearing need to b removed? or can I slide it off as the picture shows?

 

[kiwidog]

TC removal

owlridge,

See pictures for the backyard method.

Bearing does not have to be removed first,it will slide off the shaft as you push on the TC. Because you are pushing on the input gear and spacer which pushes on the bearing.

Thanks jb

 

[inkpot]

The bearing on the output shaft is just a press fit into the transfer case, and snug fit on the outer splines of the shaft. It should slide right off as you move the rest of the case away from the transmission. Be careful about damaging the mating surfaces of the two cases as they do need to fit flush with that paper gasket later. John

 

[owlridge]

I tried for the life of me with 2 huge crow bars, jack, stands, etc and it wont budge

hey inkpot, do u have a picture of the pulley u made to remove the transfer case?

can I purchase a pulley made for this specific removal?

or do I have to rig 1 up?

taking me 5 hrs to do a 5 min job lol

 

[yoda'stoy]

I tried to do the same thing you are doing when I pulled my original transfer case from the transmission. I couldn'y get it off. Then I borrowed a puller and it came off much easier but it was still had lots of resistance.
When I pulled the transfer case from the replacement setup I purchased, I was anticipating a battle again. This time it came off without any resistance. I probably didn't need the puller.
If you are really fighting it, borrow or rent a puller before you damage your case. You'll be glad you did!
Best of luck!

Sincerely,

Bill L

 

[yoda'stoy]

Here's a pic of the puller I used:

 

[apeterson]

https://forum.ih8mud.com/40-55-series-tech/131996-tranny-transfer-case.html

 

[fieldsken1]

remember the biggest hammer is always your best friend

 

[Fast Eddy]

yoda'stoy has it right. I wouldn't try it any other way. We made that device from a piece of 2" square stock, some long bolts and an assortment of nuts and washers..

 

[crushr]

You may be able to borrow a puller similar to yoda's pic at your local autozone or similar.

 

[Grinder155]

Does the transfer case come out alone or do you have to remove it from the vehicle with the transmission?

 

[SteveH]

I could not remove my '78 xfer case in the vehicle because it hit the rear support as it slid back. You could likely lower the rear of the engine/trans/xfer (after disconnecting much stuff) and clear the cross member, or just give up, as I did, and pull the engine/trans/xfer out as a unit and plunk it on your garage floor.

By doing this, you can fix all your other leaks. And for goodness sakes, get a factory service manual and read up on how to pull the xfer case. There are many redneck ways with screwdrivers, but it's useful to see how the factory recommends it be done. Some cases slide off pretty easily, and some fight you the whole way.

I found that you can no longer rent that sort of puller, so I made my own. See the Nov/Dec '16 copy of Toyota Trails magazine for a pix of the tool I made.

 

[reddingcruiser]

Buy the puller, even if it's from Harbor Freight. If you own a 40 long enough you'll own plenty of tools you might only use once or twice every few years.

 

[Travis 76]

Definitely use a puller, the bearing is a press fit on the shaft and in the case. I made one from a piece of steel channel. Drilled two holes through to bolt to the case like in the picture. Then drilled and tapped a hole in the middle to push on the output shaft. Makes a huge difference to have correct tools/methods.

 

[HoundDog]

Wanted to post up the contraption I made from random parts in my garage to remove my transfer case and add to the mud knowledge base. Obviously, first remove the five bolts holding the t-case to the transmission, three external and two hidden under the PTO inspection plate.

I used a Tekton 3 arm puller, removed the arms, and replaced them with the L-shaped brackets on chains that came with the load balancer on my HF engine lift. I bolted the three L-shaped brackets to the transfer case and pulled it off easily.

It worked well and spread the pulling load over three bolts. I let the transfer case rotate down, tied a piece of rope through the top bolt hole and supported the weight with the engine lift. Once it started sliding off and the weight was supported it came off without much effort.