Real time: separatint tcase

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Joined
Dec 27, 2005
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Tucson / Vail, AZ
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kartchcustoms.com
HELP! Any suggestions / pics, etc. on how to remove the tcase from the transmission? I've tried prybars etc. and can't get it to budge. I'm sure a puller would work but I don't know what to use. There's nothing for a gear puller to grab on to.

Thanks in advance!
 
Yep, those can be stuck pretty good. I ended up making a puller using a piece of 1/2" x 4" flat bar drilled for long threaded stock that went to the rotated transfercase bolt holes and pushed the trans output shaft, slowly forced it out by going back and forth between my bolts. You want to try to keep it coming straight back although letting it turn on the trans output shaft is OK if it helps you.

Some people have been able to hammer them apart with judicious use of rubber mallets or protected hammers.

Be careful not to break anything, and know that next time will be easier. It's just old varnish/oil that's got it gummy.

Oh, you DID take out the two bolts that are inside the transfercase, right?
 
honk said:
Yep, those can be stuck pretty good. I ended up making a puller using a piece of 1/2" x 4" flat bar drilled for long threaded stock that went to the rotated transfercase bolt holes and pushed the trans output shaft, slowly forced it out by going back and forth between my bolts. You want to try to keep it coming straight back although letting it turn on the trans output shaft is OK if it helps you.

Some people have been able to hammer them apart with judicious use of rubber mallets or protected hammers.

Be careful not to break anything, and know that next time will be easier. It's just old varnish/oil that's got it gummy.

Oh, you DID take out the two bolts that are inside the transfercase, right?

I took out three bolts across the top of the case and then two inside the PTO cover. Is there anything else that I need to remove. I have it separated from the shift linkage and speedo cable. Is it the bearing that is holding things up or the seal between the trans/transfer? Does it just "let go" or does it usually fight all the way off?

Thanks for the reply. I think I'll try smacking the crap out of it with a sledge protected by a 2x4 or something.
 
I would think that some kind of a puller is going to be needed, I replaced a few bolts back into the case loosely and used them as an anchor for a puller, I dont think the sledge is a good idea.

Just my .02

Rezarf <><
 
Three across top ? should be 2 on top , 1 on the body of tcase , 2 inside. The one on the body shoulda had an o ring or special washer to seal it.

You pulled the cone cover and took the nut off the tranny output , right ?
After you get that nut off the last bearing can be removed and then it should slide off , if not you can take off the side inspection cover and gently pry on PTO and input gear , that should do it.



You did not take the nut under cone cover off did you ????
 
peesalot said:
Three across top ? should be 2 on top , 1 on the body of tcase , 2 inside. The one on the body shoulda had an o ring or special washer to seal it.

You pulled the cone cover and took the nut off the tranny output , right ?
After you get that nut off the last bearing can be removed and then it should slide off , if not you can take off the side inspection cover and gently pry on PTO and input gear , that should do it.



You did not take the nut under cone cover off did you ????

I counted the one on the body as one of the two across the top. I took the cone cover off and removed the staked nut off the tranny output. I'll try and get the bearing off somehow, maybe from behind?
 
REZARF said:
I would think that some kind of a puller is going to be needed, I replaced a few bolts back into the case loosely and used them as an anchor for a puller, I dont think the sledge is a good idea.

Just my .02

Rezarf <><

Yeah, I agree with you. I've been using a prybar to gently try and get things to move but with no luck.

Once all the bolts are removed, should the tcase be able to rotate freely on the trans output shaft? Mine isn't. Am I missing something?
 
I meant to give the ssense that a hammer or sledge is your court of last resort. It shouldn't be necessary if your rear bearing will come out (I wasn't able to get them to budge) or if you can rig a puller of some type.

I like peesalot's hint about going through the PTO cover to try to get the gear(s) moving on the shaft. On the two that have caused me this trouble it turned out to be the years of built up burnt oil "varnish" that made everything sticky and the gears were the closest fitting things after the bearing.

If it's come back about an inch then it's probably bumping a gear against the case. The way it works is that the trans shaft pulls out through those gears and they stay inside the case, loose. There'll be at least one spacer too and that also can be gummy. You're fighting goo.
 
what about the tail shaft nut behind the cover on the back of the t-case
 
Ok, i'm a little slow. I had one of the top bolts still halfway in. Loosened it but never took it all the way out. Once that was out I was able to pry the housing out a bit using a flat prybar just enought that I could then put the housing back and then put a screwdriver into the space between the spacer and gear and get things moving.

Thanks so much for all the help!
 
Last question, what is the socket size for staked nut on driveshaft flanges?

OK, looks like a 27 mm socket. Hope I'm right!
 
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