[dion93]

Hey everyone, have taken the transfer case out to put the gears in. I am now stuck getting
The flanges off and figure I am going to need help. If anyone is able to come over and help put them in would be awesome. Carton/bottle spirits for the legend who helps. Give me a call if you can help. Missing one tool - 28mm socket cheers.

[Rusho]

Your going to need more than a 28mm socket Have you ever tryed getting a flange off??

[dion93]

Nope, I am just going by what the instruction manual says, unfortunately
they made it sound a bit easier then what it is. So now I have a day or two to
Figure everything out :s

[dion93]

Forgot my number 0432 158 488

[Rusho]

A press will make it easier also. If your putting in 6.5's you might need to take a few mm's out of the inside of the case as well. What suburb are you in?

[dion93]

Ah okay, I am probably a bit inorganised for the whole operation :/
I'm in holland park at stekkys old place

[Fatzook]

Is the zook your only transport? I have a press and flange removing tool.

[dion93]

I have until Tuesday to get them done and then I have no transport. Rego on the other car runs out. Is there any chance of me borrowing the tools sometime between now and then?

[Fatzook]

dion93 wrote:

I have until Tuesday to get them done and then I have no transport. Rego on the other car runs out. Is there any chance of me borrowing the tools sometime between now and then?

How will you move a press?

If you can bring the case over to my place tomorrow you can use my tools to strip the case etc. PM me if this works for you. I'm at Everton hills.

[dion93]

pm sent.

[scorpydude]

-double post-

[scorpydude]

I made a jig using a 20cm x 10cm x 1cm peice of flat plate. I drilled holes to match two of the flange nuts and cut a "V" (or a "C") or if you have a metal hole saw drill a hole out out to fit the socket in. Chucked it in the vice and bolted it with high tensile bolts to the back of the flange (between flange and tcase) I needed undone. I also tied the transfer case down with two ratchet straps to the bench (just in case the bolts did give way) - this also helped to stop the tcase from skewing away from the viced jig.



Opened the locking tabs on the nut with a flat screwdriver and hammer. I soaked the flange nut in lanolin about 3 times every 30minutes then put the socket and breaker bar onto it then got the tube from the vacume cleaner (about 1.5M long) chucked that onto the end of the breaker bar (probably about 2m long now).

I then slowly applied all my weight to the very end of the tubing and heard one hell of an almighty crack. I have a 1L so for the handbreak drum I mad another jig that was a bit longer to clear the length of the drum (if I do it again I'll make one jig that does everything) - it's possible you could use the jib on the other side of the drum as it's all one shaft but I didn't have luck with that, the tcase moved too much.

From then on it was reasonably easy sailing... good advice given to me that was helpful "take your time". I didn't use a bearing press, I was really worried about this (having been told by a few people "you will need a 20tonne press minimum") but the largest 3 finger gear puller from super cheap and a couple of pieces of steel tubing (brass or softer metal pipe would be better but my box section and steel pipe was free from the scrap bin at the local engineering shop) and large metal mallet was fine for getting everything on, it's really not that tight if you have them aligned properly and listen out for the sound difference when hitting between it moving and when its got no more to go it changes to a "chink". If you see it skew on the first few hits or doesn't feel right simply pull it back off, you'll know pretty quickly if it 'feels' right. For the stuff you need to push a fair way there is no problem with chucking a small amount of grease on the shaft first.

The only difficult and time consuming part after the flanges was fucking around with the "shaft end float" using shims (had to assemble and disassemble 3 times) but if I ever do gears again I'm not going to bother with this, out of the 11+ people that I talked to who put in their own gears only about 3 actually bothered with it (and all 3 of them work in some type of mechanical trade) and none of those who didn't do it have had any problems with their gears that they told me of (though it should extend the 'life' of your gears if you do it I spoke to people who were still running gears 3-5+ years after they had installed their gears without doing it and don't have any problems).

I recommend replacing all the seals, flange nuts and your speedo gear housing if it's a little mangled (my transfer case doesn't leak at all, apart from a small bit through the speedo gear housing - I regret not getting a new or god condition second hand one now)

I wouldn't try and do it without making a jig up though. I broke alot of tools and wasted a bit of money trying to do that...

If your south Brisbane and want a hand chuck me a PM.

[dion93]

Mate thank you very much for the detailed write up, would have been very helpful if inhad persued on my
Own at home. I took fatzook up on his offer and went around there an he helped me/showed me how to install them. Thanks fatzook and everyone for your help

[Rusho]

dion93 wrote:

I took fatzook up on his offer and went around there an he helped me/showed me how to install them. Thanks fatzook and everyone for your help

He is good like that...good work Mr.Fat

[Fatzook]

Rusho wrote:

dion93 wrote:

I took fatzook up on his offer and went around there an he helped me/showed me how to install them. Thanks fatzook and everyone for your help

He is good like that...good work Mr.Fat

Better than working on your junk

[Rusho]

Fatzook wrote:

Rusho wrote:

dion93 wrote:

I took fatzook up on his offer and went around there an he helped me/showed me how to install them. Thanks fatzook and everyone for your help

He is good like that...good work Mr.Fat

Better than working on your junk

My junk is 98% finished though

[Fatzook]

Rusho wrote:

Fatzook wrote:

Rusho wrote:

dion93 wrote:

I took fatzook up on his offer and went around there an he helped me/showed me how to install them. Thanks fatzook and everyone for your help

He is good like that...good work Mr.Fat

Better than working on your junk

My junk is 98% finished though

Needs a grille, and a bullbar. Oh, and the transfer case arms....