I’ve been watching a ton of videos on YouTube. And I’ve just about got her completely torn down. I noticed that my gears have a bur that has formed and although I wouldn’t think is an issue, I wanted to survey the forum’s opinion.
First time rebuilding a transfer case
- Thread starter B1oodyBuzzard
- Start date
This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.
- Thread starter
- #2
Couple more pictures. My first indication was god awful noise. Investigation determined the gear oil all moved to the transmission. Wanted to do it all at once vice band aid
Yep those are burrs. I would dress them off with a file now rather than have the metal go into the oil. How many miles on the clock and what did your kit cost?
- Thread starter
- #4
$189.00 for the kit. Unknown for the milage. I’m guessing a PO had rebuilt before. The paper gaskets had a dragonfly logo
- Thread starter
- #5
What is the best way to remove this bearing?
I have a good set of gears from a 1973 if your looking to replace those
Archie
Archie
AKPoser
SILVER Star
Not being patient enough to find the proper puller, I ended up pulling the needle bearings out and using a dremel tool with a “soft touch” to weaken the side wall of the sleeve and then whacked with a screwdriver and hammer to deform it and pulled out with pliers. Not my finest work, but got the job done.
- Thread starter
- #8
Thanks. Thats kinda what I was thinking. For some dumb reason I find myself reluctant from destroying it even though I’ll never have another use but will just sit in a random bin in my tool boxNot being patient enough to find the proper puller, I ended up pulling the needle bearings out and using a dremel tool with a “soft touch” to weaken the side wall of the sleeve and then whacked with a screwdriver and hammer to deform it and pulled out with pliers. Not my finest work, but got the job done.
A bit of something must have been homogenized into the oil based on the pattern of the burs, but it doesn't seem horrible to me. I think the gears look OK based on the amount of original cutter marks remaining and lack of an odd wear pattern but the bur edges need to be cleaned up.
I'm curious to know what caused this also. A slight misalignment between the two gear would do it. @B1oodyBuzzard did you find any worn copper bushings?
Agreed, it's not to bad - caught it in time. Could have gotten hot if there was no gear oil in there also as mentioned in post #2.
- Thread starter
- #12
Never consulted Georg directly at least for this project. My guess was the lack of oil. Luckily I haven’t put many mile on it since owning it, but I wish we would have addressed this long time ago.
Got a new tool today to pull the bearing.
Got a new tool today to pull the bearing.
- Thread starter
- #15
The idler shaft had the most obvious wear in the 6th picture. I did not notice any slop, but I definitely have done a few things out of order. Heres another of the the idler shaft and input gear.
pb4ugo
SILVER Star
I think project wrong way did a 3 part video on rebuilding a t/case.
- Thread starter
- #17
I’ve watched the orion build that Ben and Georg did multiple times. I’ve also been watching 40channel and a couple others most I come across are split cases.
I used a write up in the FAQ. Very detailed. Freezer, oven/torch and press are your friends.
There is an attachment for a slide hammer to pull it. Also, you can use a deep socket with tape over the attachment hole or dowel that is a pretty close fit, pack a little grease in the bore of that bearing slide the dowel in and whack it with a hammer. Hydraulic pressure will drive the bearing out. Works on flywheel pilot bearings too.
