Help removing intermediate gear cluster from transfer case

[flyboy]

Hi,
I’ve bravely started venturing into stripping the gearbox/transfer case. I’ve never driven the car, so have no idea the condition of either. Having also never done this before, I might be asking a few questions along the way! I’ve watched the various videos online, so was feeling confident, i didn’t get far before the first issue....following the manual, I’m at the stage of separating the two. I’ve removed the intermediate shaft and now the intermediate gear cluster won’t come out. It moves around easily, but then I get a definite clunk and it won’t come any further (it moves about a centimetre towards the opening). Am I missing something basic?

[Blknight.aus]

you need to pull the Tcase input gear and slinger out first.

the gear has to come out to allow access to a couple of hidden mounting studs and the slinger while not strictly required it as it is a just fit install through the apature its easy to hang up on and get stuck with.

the intermediate gear comes out after you remove the park brake assembly, the locking tab and nut (its on a stud that sometimes comes out with the nut) and slide the intermediate shaft out of the housing (it may require some percussion on the front end which can be done with the box in place IF you have a slim enough long enough and strong enough drift)

after the shaft is out the bearings are free to float and can slide out of position and hangup on the thrust shim/plates and their recess in the Tcase.

bit of subtle fishing with a seal hook or bent scribe will get them back in position, you'll know youve got them out of theway when you can pull the thrust plates/shims out with a pair of fine nose pliers or push them out with a skinny screwdriver.

(of course the usual way of finding out is when the cluster drops out and onto your foot, wear steelcaps, the teeth edges hurt)

[flyboy]

after the shaft is out the bearings are free to float and can slide out of position and hangup on the thrust shim/plates and their recess in the Tcase.



thanks Dave, you’re a champion!
this was the key.

standby for more basic questions 🙄