Transfercase Removal w. Trans left in place

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tomcolins

tomcolins

10 Year 15 Year
Joined
Jul 17, 2008
Threads
36
Messages
185
Location
Marfa, Texas
So, while I'm on here, you guys can see all the s--- I am getting into. Not just dumb questions about sensors and tire porn.

I replaced my clutch a few weeks back and when I was putting it all back together I noticed the front output bearing was sloppy and the seal was no good. If I hadn't been 2,000mi from home in borrowed garage space, I suppose I would have ordered the part and tackled it then... But.

Question is: can I remove the transfer case and leave the tranny in place? And if so, should the transfer adapter (or "extension housing") come with it or stay behind? The folks at Marlin who sold me the parts sez "no big deal" but I didn't pester them for details.

Anyone done this before?

Thx

DB
 
tomcolins said:
Should the extension housing come out with it or stay behind?
Click to expand...

Nope. it stays behind. Removing the extension housing would be a royal PITA with the tranny still in the truck.

I can only speak to the 4cyl transfer cases. No big deal. Unbolt it. Fix it. Put it back in.
 
Ok, case out.

One: staked but. WTF? How do I in-stake it?

Two: this case needed to be split to get the bearing out doesn't it?
I was really hoping I could just take the bearing retainer off.
 
tomcolins said:
Ok, case out.

One: staked but. WTF? How do I in-stake it?

Two: this case needed to be split to get the bearing out doesn't it?
I was really hoping I could just take the bearing retainer off.
Click to expand...

Here is a photo
image-3014641875.webp
 
liljlandon said:
Marlin crawler has an excellent instruction write-up about rebuilding cases. If you can't pry the stake up, take it off like it is. Iirc, I just zipped them off with an impact.
Click to expand...

I'll check on there. I have the FSM but it's surprisingly useless for many of my problems. We will see what marlin sez
 
So got the staked nut off. Part of the problem was the impact socket wouldn't clear the shoulder of the flange. Ground it down. Kinda hated to do that to the socket... But hell. Off now.

I was really hoping I wouldn't have to split the case to get the front output gear/ bearing assy. out. But no...

Case is split but I can't set the gear and bearing out. Bearing retainer and lock ring are off the front side, case is open. But, though the bearing is moving 1/16 th or so in and out, it won't pop free of the case.

What gives? Do I press the gear and shaft out? Then will the bearing need to be pressed out too?

Dang.

Any advice is helpful

DB
 
Bearing goes with the gear and splined shaft (to be pressed off when out)?

I whacked at it some but it only goes as far in as the slot where the snap ring was located, then stops...

Should I just whale on it harder?
 
Can you post some pics of you re-installing the Tcase. This is my next major project as my case needs to be resealed.
 
freds40 said:
The bearing you received is for the upgraded 30 spline output. We don't normally stock the factory replacement front output bearing. I'm looking around to see if I can come up with one. Can you shoot me your name and number so I can get ahold you either way?
Click to expand...

P/M me if you like. I'll write you back
 
Case is apart. Wrong size bearing sent. Bummer. Wouldn't have split the sucker open if I'd known Marlin would send the wrong part twice. Super friendly people to deal with, super frustrating to have the truck out of service waiting in parts...

I'll post pictures of the reassembly if it's helpful.

Maybe together next week?
image-1259559190.webp
 
Same as posted above, I usually just take a ratchet strap over the frame rails and under the tranny to support the tranny/tcase. With those supported, unbolt the tcase skid and take the tcase(s) out. Hardest thing of the whole procedure is lining the tcases back up with the tranny output (or dropping the cases on your chest :D )
 
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