Transfer case disassembly

[51 CJ3]

I am finally turning my attention back toward the CJ3A. When I got distracted I was trying to disassemble the transfer case to replace the bearings. Is there a trick to getting the center shaft out? I removed the lock tab and beat on it some with a big hammer and a brass punch. It refused to move but I didn’t get too aggressive for fear of breaking the case. I wanted to ask before I tear it up.
Thanks.

[bmorgil]

No trick 52 CJ3 other than, it is driven out to the rear. Heat should not be required. I use a large diameter brass drift and a large hammer. It is possible a prior repair may have used loc-tite as a sealer on the shaft. If that is suspected, some heat would break the bond. Other than that I have had good success with a few hard raps.

[51 CJ3]

I couldn’t get it with a hammer and punch even with heat. Ruined a good brass punch though. It had to go to the press which had it out in seconds. Bearings and shaft are pretty chewed up.

[bmorgil]

It sounds like you might have had some water in there Jeff. Wow that thing was stuck. I have a brass drift just slightly smaller than the shaft. You can hit it pretty good without damage. I have never had one stuck that bad!

[LarrBeard]

Ira would have said to get a Bigger FH

[TJones]

Here’s a Great Series of videos on YouTube to reassembly on the Dana 18 Jeff

https://youtu.be/3-2TgW2hE_w

[51 CJ3]

It did have water in it as did the transmission and front differential. The previous owner was a kid who thought it was fun to play in the river but never gave a thought about maintaining his ride. I haven’t opened the Rearend yet because I ran out of bench space. The yokes were wore out at the seals and oil poured out as fast as I could pump it in. The output shaft is next. I smacked it with a heavy mallet a few of times last night but it wouldn’t move either.

Thanks for the video link.

Here is a picture of the intermediate shaft and one of the bearings:

[51 CJ3]

Getting it. Had to use the press again. Bearings are stuck on the shaft. Tornado warning slowing progress now.

[bmorgil]

Beware the Tornado! I will try to make you feel better and say, I have definitely seen much worse than that. Mine was pretty bad. About all of the internals had to be replaced. Even my transmission case left me. Half the fun is checking it out I think. If you find good parts all the better!

[51 CJ3]

Tornadoes gone for now. Back work. I got the bearing cups out but the transfer case front output shaft bearing is seized in place. I managed to rip the bearing cage off of it but the race is still on the shaft. I can’t get any pullers on it and I tried heat on the bearing part along with trying to freeze the shaft but no joy. I thought I would ask before I spend the time with the dremel cutting it out. Any advice?

[51 CJ3]

Nevermind, I got frustrated enough to get the acetylene torch after it and make it glow. At that point it moved a quarter of an inch with a little prying. I was using a can of electronics dust remover trying keep the shaft cool. Made it glow again and got another sixteenth which was enough to catch it with a bearing separator and pull it the rest of the way. I had to use the press to get the rear bearing cup and the separator to get that bearing too. Used my big slide hammer to get the front bearing cup. Next up is the clip but I don’t have a proper snap ring tool for one that style and size so it looks like I get to go tool shopping. Fortunately, I know where the $nap-on truck will be about 10 tomorrow morning.

[TJones]

Yes Sir
That one tiny little snap ring is a bit of a chore to get out, makes you think somebody must of lost some sleep when they thought of how to build those Dana 18’s;):confused:

[LarrBeard]

My Dad worked for the railroad and everything was BIG - half-inch bolts were little bolts. He called an acetylene torch a Hot Hammer.

[gmwillys]

Gas Axe is my favorite term.

[bmorgil]

"Hot Hammer" and "Gas Axe" I am definitely filing those in the keeper box! Hilarious.

[GreyWilz]

Here’s a Great Series of videos on YouTube to reassembly on the Dana 18 Jeff

https://youtu.be/3-2TgW2hE_w

Good channel. My uncle got this incoming CJ3 project after we finished installing the suspension and fender flares (https://4wheelonline.com/Fender_Flares.3212) onto the Silverado and clear the garage. We'll check every video there.