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NAPA was able to get the seal for me. Before I install it, I wanted to ask when people think the best time is to install the transfer case shift rail seals… before or after installing the housing?...

Thanks for the info!

I thought I might finally get this transfer case reassembled but it isn’t going to happen today. The shift rail seal from Crown rolled the lip when I installed the front cover. The other seal is a...

Kaiser Willys sells copper gaskets for the bolts but I gave up asking on how they are installed. Gasket, flat washer then bolt makes the most sense to me because the bolt and/or lock washer would...

I thought a while back someone was talking about what about what to seal the transfer case rear bearing cover shims with. I can’t find the post. I suspect the shims will leak if left bare but adding...

I had my numbers reversed before. The shaft going into the bushing is .622 according to my calipers. It may not hurt to check that against a micrometer. The bushing gave me .623 using a telescoping...

Given the amount of time I had invested in replacing the bushing in the transfer case output shaft and lack of progress because of it… I chose to order a new shaft. It came with a new bushing...

My slide hammer type puller reaches but couldn’t get it to move. I was trying to cheat the first time by not removing the shaft from the transfer case because I don’t have a good way to secure the...

Still fighting the pilot bushing. Assuming I understood the instructions, this should have worked that bushing out but it hasn’t moved at all (measuring with calipers)
9952

I have lots of grease. A couple of different grades of wheel bearing grease, marine grease, lithium grease, aircraft grease…tubs and guns. No shortage of grease around here.

I am pretty confident...

I took several measurements of the bushing. None of them were less than .634”.

I am not grasping the how to use hydraulic force to push the bushing out. Big hole where the bushing has to come...

Found it! I keep most of my hardware in labeled cloth mail bags. When I finally found the bag I found the the snap ring. The bag had fallen into a junk box under one of the tables and got covered up...

I found the solution. The front cover has a lip that that sets the depth of the front bearing cup. It should be recessed about an eighth inch. I haven’t looked at the rear cover to see how the rear...

I have the CJ2A and CJ3A master parts list (https://www.kaiserwillys.com/master-parts-list-manual-fits-46-53-cj-2a-3a).
The snap ring I didn’t have sorted out earlier goes inside the front cover....

What keeps the D18 output gear from dragging on the case? Right now it’s dragging hard. The only part I can’t identify or find where it goes is index number 37 on the transfer case diagram. Part...

KW has always been good to work with on the rare occasion I had to get an order fixed. I did figure out I ordered it from them as part of the “intermediate shaft repair kit”. I don’t know if they...

I make enough mistakes on my own to seriously slow down progress that I really don’t need the parts suppliers sending me the wrong parts. I just found out I was sent 2 different size thrust washers...

That’s what I did after the separator quit moving the bearing. Then I started hitting pry bars and big screw drivers to push it off. Seemed kinda Bubba to me. It got the job done but I lost a brand...

I have a couple different ball joint forks like in the first link. The biggest I have will just start over the shaft. I think it’s the biggest I have seen in a parts store. It was a little hard on...

Not so good in my experience. A lot of videos from fly-by-night and shade tree mechanics. Even the ones most people accept as knowing what they are doing disregard published torque values and other...

What are people using to remove the front bearing on the D18 output shaft? It’s been so long since I took it apart I don’t remember how I did it the first time and today I am ruining new parts trying...

I didn’t think of Vaseline. That would work well. I keep some in the shop to grease o-rings. The service manual just says something like “sticky grease” and I wanted to make sure I didn’t use...

I am guessing that since there are issues with modern gear oils in the transmission there could be a potential problem with some assembly greases. What is the preferred assembly lube for the...

I have experienced the wobble. When I was a kid my Dad had a 1975(?) GMC 3/4 ton full time 4wd that would do it really bad if you got mud packed into the rims. You had to hit the brakes and get one...

Another thread reminded me of a question I have on mine. It has a steering stabilizer. I never thought anything of it before because I think every 4WD I have owned had one. I am going to have to cut...