[DarkHorse]

Hey all,

In the process of rebuilding my transfer and installing reduction gears.

I'm stuck at removing the reduction clutch hub from the main shaft:


It doesn't want to budge. I've tried slamming the case onto the bench, belting the gear off-centre to try and break the surface tension, tied some wire around the back of it and yanked then dropped the case while holding it up, belted it with a bit of 48mm as a drift... nothing is moving. I've got the heat gun pointed at it for a couple of minutes now...

I'll buy a gear puller on the way in tomorrow, but not sure I'll be able to get the claws in behind it. Any other ideas?

I've also lost the locating ball for the thrust washer at the top of the counter shaft - where the hell do I get another one of them? Other than the transfer that's in the car I guess...

Thanks in advance!

[got_bar_work]

Is there a circlip on the shaft

[DarkHorse]

Not any more. Got that off, just the gear jammed on the splines of the shaft.

Instructions say it "may or may not remove easily" and suggest slamming the whole assembly down onto a bench to jar it loose (like the trick for seperating CVs with the spring clip I guess.)

Anyway, no dice...

[DarkHorse]

Close to resorting to welding a bit of 48mm pipe to it and whaling on that... but it's one of the few bits I need to put back in.

[joeblow]

I normaly remove that shaft as a whole assembly and then use a gear puller to get it off.

[DarkHorse]

Thought about that - that'd be where the big bearing that I haven't seen yet.

How does it come out - press? Does it matter which direction? Any other clips etc I need to get out first?

Thanks for the pointer.

[DarkHorse]

This is as far as I got on the chain side, the output shaft is all done:


and on the mid section (as above):


I've got the counter shaft and input section all done and back together (minus that ball) so just need to sort out the main shaft and a couple more seals.

[joeblow]

Knock the lower front output out while the chain is still on it using a drift. Then use a puller for the bearing and remove the chain derice gear off the main shaft. Then you can remove your shift fork. Once that is done tap the main shaft out towards the rear.

[DarkHorse]

Awesome. Front output is already pulled and done, it's just sitting in posi in that photo.

Will pick up a gear puller tonight.

Thanks JB

[GeckoXL7]

Is this what you are after?

http://www.lowrangeoffroad.com/index.ph ... shaft.html

[DarkHorse]

Yep, just don't want to wait weeks for it to come from the states...

[DarkHorse]

One last stoopid question - do both of the elec switches on the outside of the case have balls under them? I've got one large BB left over, and one of the switches (with the small plastic plunger on the end) doesn't have a ball. I thought I'd grouped everything like that together, but could very easily have farked up.

[DarkHorse]

OK, I lied, two more stoopid questions...

I've used everything in the rebuild kit except one little seal - it's only about 8mm in diameter, and I have NFI where it goes. Given the condition of everything else I'm not panicking about it, but would be good to know just so I can say it's a complete job!

[Fatzook]

Is it an O-ring?

[DarkHorse]

Nope, used them.

Bottom left:

[Fatzook]

It looks like it goes in the speedo drive assembly.

[Fatzook]

Part #5.....

[DarkHorse]

Found it, thanks mate.

Of course I managed to hit the pin one too many times with the punch and split the housing, so will have to cannibalise that off the current one too.