[Aleccb1]

alright so im taking my transfer case apart getting it ready for the new gears and i've got a few problems trying to take it apart

wondering how the fork comes out?


and also cant get the speedo gear out..


anyone got any tips on how to get these out?

Thanks

[jdk81]

Small vice grips or pliers can carefully and easily remove the speedo bit, after the bolt is removed.
if its jammed, try a light tap with a hammer and chisel to rotate it a little.

I cant recall how i pull the shifting shafts out

[Teracis]

How did you get the damn case apart without removing the speedo gear bushing? Last time we forgot to remove the bolt and take that part out we destroyed a speedo gear. Anyhow yes, it's already been explained how to remove that.

From what I remember the shifting shaft will just pull out, it's held by the detent balls which are pushed into the grooves by a spring. Don't lose the balls, you should have already removed one ball and spring from the hole pointing to the bottom center of your picture. You just have to pull hard and be ready for when it starts moving to stop pulling or bits go everywhere. Alternatively you should be able to rotate the shaft which will push the detent ball back up it's tube and then you will have the side of the shaft (no grooves in the side) in position so that it should slide fairly freely. You may want to push, pull, wiggle and turn the shaft until you feel you are moving the ball, then you can just apply enough force to move the ball out of the groove.

IIRC there is (going from the outside to the inside) Detent plug, spring, ball, shaft, ball, shaft, ball, spring, case. So depending on which shaft you are trying to move you may have a hard time, if you pull the "inner" shaft until the ball drops into a groove I think that will give additional clearance for the shaft closest to the edge of the case to push the ball out of the grooves. It's been a while since I rebuilt my case, hopefully this helps.

Take a look at the installation instructions that come with lowrange gear sets to get an idea of what I explained above, once you can see what you're working with, you should be able to understand why it's hard to move and how to get it out. It's also awkward to put them back together, don't lose a ball and make sure you put them back in correctly or it can jump out of gear under load.

[Aleccb1]

The case lifted up far enough for me to take out the other gears and slide the fork out of the shaft, but i finaly managed to get the shafts out, and the speedo gear.

Thanks for the help