Replacing 5th gear boot on H55f transfer case...help greatly appreciated

[ghillie989]

Good evening,

as in the title, im trying to replace the 5th gear boot located on top of the transfer case and I cant work out how to release the pin which is located in the notch in the shaft!

anyone had experience with this before?

best regards

 

[SuperDuperCruizer]

For the one I recently worked on, there was bolt and a tabbed washer. The washer has 3 tabs that are bent to secure the position of the bolt.

You’ll need to bend the tabs flat to get a socket on there. Once you remove the bolt and washer, the arm/lever slides upwards to separate it from the 5th gear fork/shifter of the extension housing. The boot can be removed once the arm/lever is off. The boot is seated in a groove that holds it in place to the transmission cover.

I don’t have a good picture of it. Hopefully, you can get an idea of what I’m describing. I was disassembling the transmission. So, the bolt and tabbed washer were removed in this photo, but the arm/lever is still in place. Ignore the hex socket being removed in the photo. That’s unrelated to what I described above.

 

[ghillie989]

thankyou for your reply,

thats the stage i got to, i managed to get the nut out , but it wouldnt let me release the lever and i couldnt manage to pull it up out for the way!

is it possible to pull it up out of the way? i cant see how else you can change to boot without dismantling it, which im not interested in doing!

thansk again, best regards

 

[Billyfj7312ht]

You have to remove the aluminium case cover on top. PITA. Then there's a gasket to replace. Made me think the rubber glue to repair the boot might have been the way to go.

 

[SuperDuperCruizer]

Notice in the picture attached, you can see the threads on the arm/lever for the bolt I was referring to. It's actually sitting lower/closer to the extension housing than it should be. There's a notch in the actuator (part within the boot) that the arm/lever aligns with.

I'm pretty sure I didn't need to remove the 5th gear housing or transmission cover to get the arm/lever removed. I would unseat the boot, then wiggle the shifter just in case the actuator is placing torsional force on the 5th gear shift fork the lever bolts to. The arm should be able to move up and down freely once you have the bolt out. The boot might snag onto the arm/lever; however, if you've unseated the boot there should be enough give to remove the arm/lever.