[zooky08]

im rebuilding a wt transfercase atm and i cant seem to remove the shift fork out off the case. i manage to get it all apart, but i need the shift fork out to reinstall every thing back together. ive removed the detent ball but still doesnt budge. hit it with a soft mallet, even try pressing it out. any ideas?

cheers

[abclarke]

afaik you shouldnt have to remove the shift fork? If its the bit im thinking about?

[zooky08]

yea its got to come out. even the reduction gear instructions saids so.

[xedent]

With mine I had to knock out a roll pin! That's what my 4.9 instructions made me do.

[zooky08]

were is the pin located? ive got evey thing unscrew out of the housing accept the shift fork.

[Fatzook]

I've rebuilt dozens of sierra cases, and installed gears of different ratios, and I've never had to remove the shifter rods from the front housing. There are no seals or O-rings in their assembly, only detent balls, which can be a PITA to re-fit.

[zooky08]

i cant put it back together. im having trouble. i have the gears installed into the rear housing, then when i go to put middle housing on, i cant get the fork around under the couter shaft gears to go onto the high/low gear

[Fatzook]

zooky08 wrote:

i cant put it back together. im having trouble. i have the gears installed into the rear housing, then when i go to put middle housing on, i cant get the fork around under the couter shaft gears to go onto the high/low gear

Lift the idler gear and the input gear up a little. The bearing at the base of the input gear will re-seat itself, as will the idler gear if you give it a little turn so they mesh together.

its an arkward motion, but it does work I assure you. I will have a case appart tomorrow, so if you are still struggling I will get some pics for you. ( with my 3rd hand )

[zooky08]

thats would be good thanks

[31zook]

Fatzook wrote:

I've rebuilt dozens of sierra cases, and installed gears of different ratios, and I've never had to remove the shifter rods from the front housing. There are no seals or O-rings in their assembly, only detent balls, which can be a PITA to re-fit.

X2.

[Teracis]

The rods should come out pretty easily. I've had trouble trying to move them because the detent ball locks them, if you twist the rail around, it will push the ball back and now your sliding on the part without the grooves for the balls to lock into, slide it wherever you need, turn it back.

If you take them out it can be a real struggle to get them back in, for reasons mentioned above. I think I used a screwdriver or similar to push the ball down far enough, slide it out as you slide the rail back in and hopefully all good...

[scorpydude]

Fatzook wrote:

Lift the idler gear and the input gear up a little. The bearing at the base of the input gear will re-seat itself, as will the idler gear if you give it a little turn so they mesh together. Its an arkward motion, but it does work I assure you.

+1

If your SE Brisbane I can come round and give you a hand.

[zooky08]

ive got the detent ball out off the case. it slides almost out and then gets cour about a inch from the end,

scorpydue, im 2hrs north of brisbane so pretty far. thanks for the offer though

[Fatzook]

zooky08 wrote:

ive got the detent ball out off the case. it slides almost out and then gets cour about a inch from the end,

scorpydue, im 2hrs north of brisbane so pretty far. thanks for the offer though

There is a detent ball between the two rods as well. You need to get the detent ball to sit in a notch on the rod you are not removing, then rotate the other rod. It should come out then.

But you have been warned.... Its a shitty job getting it all back together

[zooky08]

okay well im gonna try your idea soon fat, ill see if i can get it

[zooky08]

I f#*ked it so gotta find another case now. Thanks for you help.

[Scales]

Yikes!

whatd you do to ruin it? so i can learn from your mistake when i do mine.

[zooky08]

Dont hit cast iron to hard

[abclarke]

zooky08 wrote:

Dont hit cast iron to hard

I thought the cases were only cast ally?

[zooky08]

Wasn't the case that broke

[31zook]

Haha, I can send you another selector if you like.

[zooky08]

Wasn't selector either I smashed the teeth off the spline that te circlip goes into to hold the front output shaft sliding cog thing, also decked the thread on the end of the shaft

[Fatzook]

zooky08 wrote:

Wasn't selector either I smashed the teeth off the spline that te circlip goes into to hold the front output shaft sliding cog thing, also decked the thread on the end of the shaft

Sounds shit

Buy a copper mallet for your next attempt.

[Fatzook]

Not sure if this is any use to you, but I have a brand new main shaft here ( the bit with the spline you broke ). It owes me $180US plus freight, but if you bring your case and $200 down here on Sunday I'll press all your bearings etc onto the new shaft and show you how to fit it all.

I also have a new HD front output shaft, new internal needle roller for front output shaft, new speedo drive gear and housing, new rubber boot and spring for transfer shifter, thrust washers, O-rings, shifter bushes, prop shafts, gaskets etc....

[zooky08]

Well I do need another case or either two new shaft. I'm I rough barsted and destroyed the rear out put and the front input shaft threads. Me being dogy tried cuting thread back to fix up but made a mess I new two new nuts aswell.
Every thing is good asides two shafts and two nuts.

[Fatzook]

zooky08 wrote:

Well I do need another case or either two new shaft. I'm I rough barsted and destroyed the rear out put and the front input shaft threads. Me being dogy tried cuting thread back to fix up but made a mess I new two new nuts aswell.
Every thing is good asides two shafts and two nuts.

I'll see if I have the other shaft you need in the morning. It will be used though.

And you can get new nuts from suzi auto spares at springwood. Just get him to post them to you on monday. Cheaper than LROR on the flange nuts BTW.

[zooky08]

Don't mine if you have two used shaft or one.
Yea I'll order new nuts.

Pm sent

[Fatzook]

zooky08 wrote:

Don't mine if you have two used shaft or one.
Yea I'll order new nuts.

Pm sent

My main shaft was toast. Seems its getting more and more common to find them that way. Thats why I keep one here.......

[Scales]

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

is this the one you are referring to?

[zooky08]

Yep that's the shaft I smashed the spline on.