Help with SYE install please (pics)...

cmassey_2006 · 07-19-2006, 10:13 PM

Ok, I am trying to install my SYE kit, but I can't even get the dang output housing/carrier to seperate from the rear TC half. I've been following all of the instructions in the kit, a couple online write-ups, and a FSM and I don't know what I'm doing wrong or what step I missed.

I've removed the slinger, pryed the seal off and removed every snap-ring and lock-ring I could find, and removed all 5 bolts on the main output housing. I still couldn't get it off, so I gave it several good wacks with a rubber mallet and it's still stuck on there. I didn't think RTV gasket maker could have such a strong bond! Is there something I missed and need to do in order to get this off? I'm confused and frusterated, so I thought I'd take a break and ask you all.

Here are some pics of what my output housing looks like currently (sorry, I still am not allowed to post pics):

http://www.imagestation.com/8294420/3991738286

http://www.imagestation.com/8294420/3991735098

http://www.imagestation.com/8294420/3991738116

Here are all the snap/lock rings I've removed:
http://www.imagestation.com/8294420/3991738031

Thanks alot in advance for your help!!!

**CJ7-Tim** · 07-19-2006, 10:21 PM

Here are 2 SYE install writeups with lots of pictures.

Link to SYE writeup #1
.
Link to SYE writeup #2

hmmhoyhoy · 07-19-2006, 10:25 PM

It will come off, they can be huge pains. One thing you might want to do is directly heat it with a blow torch, some would advise against this but I was told by a mechanic it was ok. It will come off after a while of bangin at it. Also make sure you cut your fork selector rod depending on the kit and year of tcase you have

conrasm · 07-19-2006, 10:43 PM

You have the newer style TC, but it looks like you got all the hardware off. (I didn't have any snap rings in mine, only lock rings.)If may be the RTV holding it on. I couldn't believe how hard I had to whack the end tail housing on my TC before it would come off.

It looks like the housing is going to have to come straight off since the bearing will keep it from rocking. Have you tried tapping it to make it spin...to try to break the RTV seal?

Once the housing is broken loose, the shaft should have some movement, but the oil pump will keep it from moving a lot.

cmassey_2006 · 07-19-2006, 10:47 PM

Thanks for the help and the extra write-ups; they'll be another great reference for this install!

So, I take that it's normal for the housing to be stuck on there real good? I wasn't sure if it was stuck because I missed a snap/lock ring or another step and didn't want to possibly damage my TC by trying to force it off. The FSM says "8) Tap rear retainer with rawhide or rubber mallet to loosen sealer bead." and I'm like yeah, tap...sure. I've wacked it several times with a rubber mallet and it's still stuck on there really good.

One of those write-ups posted here said they used a gasket-scraper to loosen the housing and the other said they used a pry-bar. Which method do you think is safer to use, meaning less likely to damage the rear half of my TC? Thanks for all the help so far and I appreciate the quick replies!

cmassey_2006 · 07-19-2006, 10:53 PM

Quote:

Originally Posted by conrasm

You have the newer style TC, but it looks like you got all the hardware off. (I didn't have any snap rings in mine, only lock rings.)If may be the RTV holding it on. I couldn't believe how hard I had to whack the end tail housing on my TC before it would come off.

It looks like the housing is going to have to come straight off since the bearing will keep it from rocking. Have you tried tapping it to make it spin...to try to break the RTV seal?

Once the housing is broken loose, the shaft should have some movement, but the oil pump will keep it from moving a lot.

Thanks for the reply. What do you mean by "make it spin"?

The large snap-ring you see in my last photo was in the very back on the housing and I had to use some large internal snap-ring plyers to squeeze/compress the ring and pull it out of the housing opening. Then I removed two small lock-rings off the actual output shaft and some metal ring that just slid off the shaft.

cmassey_2006 · 07-20-2006, 01:57 PM

*bump*

I've tried using a gasket scraper to wedge in between the housing and TC to see if I could loosen the bond, but I can't seem to get the scraper in there.

Has anyone run into this problem and what was your solution? Sorry for the persistence, but this is my first SYE install. Thanks in advance for your help!

**FitchVA** · 07-20-2006, 02:08 PM

it's been a while since i did mine. but i do remember having some "fun" getting the case apart. if i recall, i make sure to hammer on mine all around it from every side. then i took a putty knife and hammered it into the seam all around the case to kinda try to brake up the rtv.

but i do remember the was a bugger getting the case apart. don't give up. but at least you're replaceing the tail cone so no worries if you mess that up

cmassey_2006 · 07-20-2006, 02:22 PM

Thanks once again Fitch! I didn't try to tap/hammer the gasket scraper into the seam because I was afraid that I might damage the mount surface on the rear TC case half. But I'll try that with the putty knife tonight (when I get off work) and see how that goes. I'll let you guys know if I was successful or not. Thanks again for your solution!

**XJ99** · 07-20-2006, 03:36 PM

Here's the video:

http://www.crgrissom.com/jeep/SYE.wmv

hmmhoyhoy · 07-20-2006, 05:47 PM

I just did mine and it was stuck on there good, a friend hit it while I tried to get somethin in there and after a while that worked for us

cmassey_2006 · 07-20-2006, 06:16 PM

Cool, thanks guys. At least I know it's not just mine. I'm about to get off work, so I'll let you all know how it goes. Thanks again!

JBassXJ · 07-20-2006, 07:44 PM

holy crap that seems like a lot of work! how many hours does that take if everything goes fairly smoothly?

**XJ99** · 07-20-2006, 08:19 PM

Quote:

Originally Posted by JBassXJ

holy crap that seems like a lot of work! how many hours does that take if everything goes fairly smoothly?

10 mins.

http://www.jeepforum.com/forum/f9/10-minute-sye-install-202814/?highlight=%2Asye+install

johnsoninc86 · 07-20-2006, 08:57 PM

I had to go get two three jaw pullers and link the links from the two together so that it makes it long enough to get on the tcase shaft and reach around to the ears on the output housing. You need about 10-12 inches of reach, and the biggest three jaw puller we had was an 8 or 10. Hope that helps!