Thread: 80" transmission - Xfer case Questions??

intermediate gears have to come out first, in fact you have to do that to get access to all the bolts that hold the transfer to the gearbox. There is a small bolt and a tab holding the intermediate shaft in, undo that and pull the shaft out while holding the gears and once the shaft is out the gears lift out.

If you want to pull all the gears out then you need a cut down gear race to get the front bearing out of the case. Or a made up piece that is the right size. It makes more sense if you have the manual to follow as it gives you the correct order to do things in.

Thanks for that,

Part of problem is that my manual is missing the pages and paras from C29 to "driveshaft" chapter. Someone is sending me a copy.

I have removed the shaft for the intermediate gears, did think they would just fall out - Didn't, and I didn't want to force anything. So the intermediate gears should come out if the "tabbed" shaft is removed? And yes there is a "casing" nut hiding there.

Can turn up whatever I need to drive a bearing out. :0)

Ta

RF

I have never had the intermediate gears not just fall out, usually you need to make sure you have hold of them before taking the shaft out. There are two needle bearings inside the gears that the shaft goes through and there are normally some thrust washers at each end. It is possible that something in that lot are jamming up and not allowing the gears to come out but it isn't normal. The series 1 transfer case has a smaller intermediate shaft and therefore smaller bearings than the later ones but it shouldn't make any difference to the gears coming out.