Transfer case puller tool - what am i missing here?

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I don't know enough about transmissions to really comment too much here, but the cheap option is to replace it. I've seen 4-speed transmissions and transfer cases on Craigslist for a couple hundred bucks.

That said, if George says run it, run it!
 
Tearing down transfer case tonite, stuck here:

IMG_5320trxfr.webp

How do I press this first shaft out without a press and the SST that goes between the gears?
IMG_5320trxfr.webp
 
Have you looked thru some of the rebuild threads on here?!

2x4 and a dead-blow hammer. 2 minute job ....

Georg @ Valley Hybrids
 
Vae Victus said:
Orangefj45 ignore the PM. Thanks for that, I'll continue with the rebuild and see how long it lasts.
Click to expand...

Yes, it is just tough to find the right one at the right time - out of 70 threads I'm subscribed to, not one is what I feel is a good Trxfr Case rebuild thread.

I'll look some more.

First time jitters....
 
Like Georg said, use a 2x4 to keep the low-speed gear from moving forward, then drive the shaft and high-speed gear out the front using a dead-blow hammer.
 
Ok I got it out - the main shaft. However, what was not clear in reading the threads posted here was the fact that the small gear was needing to come out of the bottom hole with the shaft. Once I figured that out it took a few blows with a dead blow. The threads helped, but didn't make that clear. So I'll clarify.

image-749090071.webp
Small gear sticking out of the hole.

image-343239631.webp
Shown from inside - note small gear sticking out hole.

image-2905263701.webp
Support the large gear - that is what you are separating.

image-4162137194.webp

image-2775386319.webp

image-2461338106.webp
image-749090071.webp
image-343239631.webp
image-2905263701.webp
image-4162137194.webp
image-2775386319.webp
image-2461338106.webp
 
Last edited:
merlinridesagain said:
Great pictures and explanation!

I used the links I posted just for doing a re-seal/gasket job, never gone all the way in...
Click to expand...

Coolerman's page is the bomb. Just looking at all his mini-projects on his website is overwhelming. I kept saying, "Gotta do that, and that, and, yep, that one... dang!"

I wonder what happened to the guy who was posting the nice explanation in the first link - he just disappeared. Kinda like the western movies where they walk into the cabin and the food is still hot on the table but everyone is gone.
 
Anyone know the clearance on the bearing/washer and the high speed gear on the output shaft? I've driven the bearing on but it still has a 0.48mm (0.019 in) gap, enough to rattle a bit.

1975 FSM is mute to the measurement.

image-1832358763.webp
image-1832358763.webp
 
I like stock cases to come in between .008" and .012" but .019" is too much if you ask me.
AA offers stepped washers. They come in the Orion kits. They're also available separately and I keep a handful in stock just in case.
If you take a close look at the stock flat washers, you'll see that some of them have a fairly heavy chamfer on the inside edge. If you need less clearance, then try the washer with the most chamfer. If that isn't work, you'll want to use the AA washers.
Hth
Georg @ Valley Hybrids
 
orangefj45 said:
I like stock cases to come in between .008" and .012" but .019" is too much if you ask me.
AA offers stepped washers. They come in the Orion kits. They're also available separately and I keep a handful in stock just in case.
If you take a close look at the stock flat washers, you'll see that some of them have a fairly heavy chamfer on the inside edge. If you need less clearance, then try the washer with the most chamfer. If that isn't work, you'll want to use the AA washers.
Hth
Georg @ Valley Hybrids
Click to expand...

I'm thinking it is just not seated all the way down yet, but it may be as far as the shaft will allow.

What is the stock washer thickness? I only have the two washers that were in the transfer case - 1 for each end, so there's no opportunity to compare chamfer and swap it out.
 
Vae Victus said:
Anyone know the clearance on the bearing/washer and the high speed gear on the output shaft? I've driven the bearing on but it still has a 0.48mm (0.019 in) gap, enough to rattle a bit.

1975 FSM is mute to the measurement.
Click to expand...

Weird. The 1980 FSM doesn't have it either. Both show the idler shaft thrust clearance to be .005-.018. I'm sure I read it somewhere. Probably the Orion manual.

I seem to remember being perturbed that it also was not in the Orion instructions. I mentioned it to them during my adventures in thrust clearance, but they didn't seem interested in adding anything.

http://www.advanceadapters.com/downloads/Orion0.pdf
 
Fast Eddy said:
Weird. The 1980 FSM doesn't have it either. Both show the idler shaft thrust clearance to be .005-.018. I'm sure I read it somewhere. Probably the Orion manual.

I seem to remember being perturbed that it also was not in the Orion instructions. I mentioned it to them during my adventures in thrust clearance, but they didn't seem interested in adding anything.

http://www.advanceadapters.com/downloads/Orion0.pdf
Click to expand...



You might want to check that , ........ 2nd page, G22 thrust washers:



different than stock measurements. The shaft and gears should be set at .008"-.012" of end play. We now include two new thrust washers to help set up the transfer case with the correct end play. These thrust washer are stepped. One side has a recess of .015" - .017" and the other side of the washer has a .008" - .010" recess. So by using one side or the other of the washer or using your stock washers, you should be able to get close to the required tolerance. P/N O60080 (2 required) If you should have any further questions please call us @ 1-800-350-2223.


That has been in the Orion manual as long as I can remember them having the stepped washers in the kit. And that's been a few years now.

Georg @ Valley Hybrids
 
Fast Eddy said:
Weird. The 1980 FSM doesn't have it either. Both show the idler shaft thrust clearance to be .005-.018. I'm sure I read it somewhere. Probably the Orion manual.

I seem to remember being perturbed that it also was not in the Orion instructions. I mentioned it to them during my adventures in thrust clearance, but they didn't seem interested in adding anything.

http://www.advanceadapters.com/downloads/Orion0.pdf
Click to expand...


What are the pros and cons of an Orion? I've seen it mentioned 100 times, but I've never researched it. What does one retail for?
 
orangefj45 said:
You might want to check that , ........ 2nd page, G22 thrust washers:

different than stock measurements. The shaft and gears should be set at .008"-.012" of end play. We now include two new thrust washers to help set up the transfer case with the correct end play. These thrust washer are stepped. One side has a recess of .015" - .017" and the other side of the washer has a .008" - .010" recess. So by using one side or the other of the washer or using your stock washers, you should be able to get close to the required tolerance. P/N O60080 (2 required) If you should have any further questions please call us @ 1-800-350-2223.

That has been in the Orion manual as long as I can remember them having the stepped washers in the kit. And that's been a few years now.

Georg @ Valley Hybrids
Click to expand...

Georg, I missed that. Thought it was idler gear they were talking about.
 
Here's a pic of the recessed washers AA offers. They're included in the Orion kits. I stock them also.

Georg @ Valley Hybrids.
image-240581450.webp
 
Here's a pic of two OEM thrust washers. If you look closely, you can see that the one on the left is chamfered quite a bit more on the inside edge.

Georg @ Valley Hybrids
image-1198345322.webp
 
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