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Unread 05-23-2013, 02:24 PM   #1
attworth
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1979 CJ7 
 
Join Date: Jun 2009
Location: West of Topeka, KS
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How to remove T-case without dropping output in trans?

Well, I was finally getting the Jeep back together after about a year of it sitting. I had a bad throw-out bearing, which I just replaced. Got the transmission in no problem. Went to get the T-case in, and the gears wouldn't line up. I pulled back on the T-case, knowing what was about to happen. And it did. Output shaft fell out, and all the needle bearings with it.

So, two questions -

1. Is there any way to "mod" the trans so it won't do this ever again?

2. Is there any way to put the bearings back in a "field-expedient" manner, i.e., without removing the transmission again? I haven't been inside there since I rebuilt it about 4 years ago, so I'm a little shaky.



The Jeep Gods have not been kind to me lately.

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Unread 05-23-2013, 03:26 PM   #2
Ivehad4
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The main shaft of the transmission came out? If that's the case, something is quite wrong in the transmission and it needs to be fixed. You cannot replace the needle bearings b/t the main shaft and the clutch shaft without taking it out and completely tearing it down - including dropping the cluster gear.
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Unread 05-23-2013, 03:42 PM   #3
attworth
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Quote:
Originally Posted by Ivehad4 View Post
The main shaft of the transmission came out? If that's the case, something is quite wrong in the transmission and it needs to be fixed. You cannot replace the needle bearings b/t the main shaft and the clutch shaft without taking it out and completely tearing it down - including dropping the cluster gear.
The rear output. From my understanding this is normal when you pull the tcase out and it doesn't "release" since the gears are helical requiring you to pull back pretty far. It came out fine the first go around but this second time didn't work out.
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Unread 05-23-2013, 04:22 PM   #4
LumpyGrits
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That ain't su'pose to happen ever........
You got other issues inside that box.
What tranny and t'case?
LG
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Unread 05-23-2013, 04:49 PM   #5
stamp32
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Yeah like the others have said that should not happen. Sounds like you might be missing a snap ring causing everything to shift.
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Unread 05-23-2013, 05:27 PM   #6
only in a jeep cj
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I think I know what the op is talking about. I only had a T150 / Dana 20 combo briefly as I bought them just to install in a jeep I was selling. I remember shifting through the gears as I spun the front input shaft, the tcase was not attached, and it started clunking and getting stiff. Then I saw that the rear bearing housing had walked out from the rear of the case. It didn't go right back and I don't remember the exact steps, but it was a royal ***** to get it back. I had to remove the cover or shifter and go in and hold back this part, preload another, slide a third, etc. I remember thinking what a crappy deal and someone with no transmission experience would be screwed on this one. So it's a t150 deal .... The tcase holds the rear on place when they are bolted together.. Glad I sold that jeep
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Unread 05-23-2013, 05:49 PM   #7
attworth
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Ed has it right. The shaft doesn't literally come out, but it shifts enough for those support bearings to fall out.

It did this the very first time I pulled the transfer case off several years ago. I rebuilt it at that time because it needed new synchros. A quick inspection tells me that there isn't anywhere that I've missed a snap ring. I guess I'll find out when I pull the trans again unless someone comes along with an easier method.
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Unread 05-23-2013, 08:57 PM   #8
Ivehad4
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I went back and looked at pics of my last rebuild and I can see what you're talking about, just never occurred to me before. In order for that to happen, the rear bearing housing has to be pretty loose in the bore and the 1st/R synchro asm. would be in the 1st gear position. I'm wondering why it's such a struggle to separate the boxes for you. You should put the transmission in neutral and have the TC in 4 HI. This way you can turn the ouput shaft of the TC to spin it off of the transmission output gear. You probably should inspect the TC input gear arrangement - including the female gear in the center of the input. Look for any signs of wear that would cause it to hang up at assembly or disassembly.

Not sure if this will work but you might try "staking" the transmission case around the rear bearing housing with a punch to tighten it up some. Make sure its fully seated before you try that.

Unfortunately, as I mentioned above you'll have to drop it all and do the transmission reassembly. The reassembly isn't that hard IMO, it's taking it out and putting it back in the Jeep that I dread. Good Luck.
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Unread 05-23-2013, 09:15 PM   #9
attworth
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Quote:
Originally Posted by Ivehad4 View Post
The reassembly isn't that hard IMO, it's taking it out and putting it back in the Jeep that I dread. Good Luck.
Agreed.

The trans was in Neutral, but I think the case was in Neutral as well. Thanks for the tip about 4HI. Hadn't thought about that.

Thanks for the input folks. Not looking forward to this.
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