Transfer Case Rebuild & Modification (High & Low Range Gears and Part-Time 4wd Kit) (1 Viewer)

[CharlieS]

Timmy and Georg, thank you so much for doing the time consuming work to share this with us. These videos contain so much valuable (hard earned) knowledge, that most of us would never have access to. Thank you!

Having torn a couple of these apart and reassembled them using the FSM, I have a decent sense of the basics, but watching these videos provides so much in depth information, best practice, and tricks of the trade. It is hands down the best, most thorough, technical content I've seen.

I wanted to say thank you again. I tore down my spare transfer case yesterday in the process of installing my Sumo gears. This is my third transfer case teardown, so not a complete newby, but still not experienced. With the tips in this video series, it made the job so much easier. I managed to disassemble the whole assembly without any breakage. I used a ton of the tips from the teardown video. I'll be going back to review the others as I dive into pressing off the gear stacks. Thank you so much for doing this Timmy (@Timmy65) and Georg (@orangefj45). I am very appreciative.

 

[CharlieS]

I asked Georg to take a measurement of the Proto puller arms for me. When I get his response, I'll comment back here.

10" overall, 7-1/4" max depth on my longer arms.

 

[EricG]

Fantastic stuff guys, thanks so much!

I'm stuck on getting my front shaft out of the housing though. Been beating on it hard for awhile wit dead low and brass hammers but no apparent progress. And, of course, I don't have that nice jig and huge press.

Any suggestions?

 

[orangefj45]

Fantastic stuff guys, thanks so much!

I'm stuck on getting my front shaft out of the housing though. Been beating on it hard for awhile wit dead low and brass hammers but no apparent progress. And, of course, I don't have that nice jig and huge press.

Any suggestions?

You can use a small propane torch to warm up the bearing some. But if the output shaft gets hot it won’t help.

 

[EricG]

You can use a small propane torch to warm up the bearing some. But if the output shaft gets hot it won’t help.

Thanks - I managed to get it off by pulling the other piece off with a gear puller first.

I guess with a 50 ton press you can push it through all in one go! But us mere mortals with a rubber hammer might need two steps