Real Time Help Removing Transfer Case Cover (1 Viewer)

[fred]

I discovered that Kragen's will let you "borrow" tools that you only rarely need. Borrow, in this case, means that you put down a deposit, take the tool home, use it, and when you return it, they cancel the deposit. Zero cost to you.

I got their 6 inch across bearing puller to yank the stuff off the transmission output shaft. And then foolishly returned it, forgetting that I still needed to pull the stuff off the rear output shaft.

I ended up taking the intermediate case, the front and rear shafts, and my replacement bearings and races, and sweet talked the nice guys at the place i've gone for driveshaft stuff into popping this stuff off and on using their press. Well under an hour, they were happy to get some extra income. Only disaster was when they tried to pull the seal for the speedo cable, and destroyed it while leaving it inside!

I eventually got it out "by other means"..

frankly, most of the gears and bearings and seals can be removed by hand, or pried off, or, worst case, using a gear puller, and replaced with a mallet and a collection of sockets or pipe or wood blocks.

As you would have to do if you were doing this in the field.
Yet another fine feature of the cruisers, and why they are the champs of the third world.


For the front and rear output shaft

 

[orangefj45]

did you replace the pocket bearing located in the front of the main shaft? they can be a pita.

georg

 

[fred]

georg,
I assume that you mean the pilot bearing inside the back end of the front output shaft, which the front end of the REAR output shaft rides in? Yep. A PITA to remove, yes. Pretty much going to destroy it when you remove it.
Apart from this one and the speedo seal, all of the other seals and bearings can be kept as emergency spares. (Better than NO seal at all...)

 

[Von Hayek]

I'll have to add a press to my Christmas list Along with bead blaster, parts cleaner, and humongous air compressor.

i thought we were talking about the pressure switches?!

it's pretty common for the cases to be a little stubborn when trying to split them. even the smallest rust build-up on the rear portion of the idler shaft ( where it sticks out of the rear case half ) can cause it to bind in the rear half. i usually use a brass drift and hammer to knock it thru the case as i'm removing the rear half.

these cases really are a great design; they're easy to remove and to rebuild. just takes a little time and patience as well as some specialized tools. fwiw, you do not need a bearing seperator. i remove them in a press and it work very well and i can have both main shaft bearings off in less than 3 minutes.

hth

georg @ valley hybrids

 

[orangefj45]

georg,
I assume that you mean the pilot bearing inside the back end of the front output shaft, which the front end of the REAR output shaft rides in? Yep. A PITA to remove, yes. Pretty much going to destroy it when you remove it.
Apart from this one and the speedo seal, all of the other seals and bearings can be kept as emergency spares. (Better than NO seal at all...)

yup, that one. i call it the main shaft since it handles most of the work in the t-case and has the most gears and whatnots attached to it. i consider the other one the front output shaft. pretty common lingo when talking about t-cases, be it domestic stuff or imports.

fwiw. they're not as difficlut to remove as their earlier counterparts in the one-piece cases in earlier cruisers. i use a snap-on pilot bearing puller with a little bracket and spacer i made and that system works very well. sometimes they do put up somewhat of a fight. but in the end they always submit......

 

[orangefj45]

I'll have to add a press to my Christmas list Along with bead blaster, parts cleaner, and humongous air compressor.

werd.

i'm looking to upgrade my bead blasting cabinet right now to something newer and slightly larger. they save soooo much time.

as for compressors, i had the chance to buy a screw compressor about 3 years ago and pulled the trigger. one of the best tools i've bought for the shop. i can run the bead blaster all day and not have to worry about the compressor keeping up.

you can pick up a cheap press from harbor freight. they work just fine for occasional usage.

hth

georg @ valley hybrids