Well most of the parts to repair my sheared xfer case rear output shaft have arrived. Thank you Randy for the output shaft - looks good <img src="/forums/images/graemlins/kewl.gif" alt="" />. I also received a replacement flange nut and o-ring from St. Charles, but they are too big <img src="/forums/images/graemlins/frown.gif" alt="" /> - gonna have to call Merlin in the morning ...

In any event, I pulled the transfer case and took out the "gear side" of the shaft. It has eight bearings secured between two races on it and is secured by a c-clip. I removed the clip, but the bearing "pack" won't budge. I have a two-pronged gear puller. Can I use that? I really don't want to mar the outer race as I'm going to be / try reusing the bearings.

Second problem - getting the flange nut off. The flange nut has two "detents" in the side; do I have to "pop" these back out before I remove the nut, or if I can apply enough force should it come out anyway? If I have to "pop" the detents what is a good way to go about it?

Along those lines, with the sheared output shaft, I don't have any resistance for the part remaining in the tail of the xfer case. I'm thinking I'm going to have to have a couple of bolts welded onto a long steel plate to get the leverage I need to remove the nut. Any other thoughts on this? I suppose I could also re-attach the drive-shaft to half of the flange and try to use that towards the same end?

If any of you Zu Gurus have any ideas, I'd love to hear them. I'm getting sick of taking the bus to work (again <img src="/forums/images/graemlins/drunk.gif" alt="" />).

Thanks in advance,

Jim,
Give me a call. I'll help you if you want.
I have a mtb race to finish last in on Sat, but we can figure something out.
I used a piece of steel that I drilled to match the rear DS flange for two bolts. You can then use the piece of steel as leverage to break the nut free. I still have it laying around if you want to use it.

All that holds the output gear cluster in place is the flange on the outside and the c-clip you refer to on this inside. Once these are removed, it should slide out. I'm not sure the extend of the damage you did, but that may be why its not coming out freely for you.

No, you don't have to pop out the "detents" on the nut to remove it. If you have a big enough impact gun, it should just come off. I clamp the flange in a vise and hit the nut with my impact.

-Rob

What you are describing is a staked nut. Yes, you want to find a small punch to un-stake it. It does not have to be perfect, but it has to be better than it is now. Yes, you can rip it off with an impact, but you risk damaging threads. (Not that it matters on this pieces, but it may help you in the future.:D)

Good Luck,
Michael

Dude. Pictures. <img src="/forums/images/graemlins/kewl.gif" alt="" />

I wanna really see what earned you all those awards...

Glad to help, Jim... I'm tickled that a dusty part I was never going to use can be installed and save you some bucks. After you get the flanged nut off (as others have mentioned, use a hammer-driven punch to clear most of the staked portion, then brute-force unthread it with a big impact gun or breaker bar and a big old spanner).

Eight balls on the tail of the mainshaft, eh? I'm guessing that you will find 6 or 12 balls in the tailshaft bearing (the one that rides on the middle of the shaft I sent you) -- I'm guesing that because of the 6 little heat signatures at the break. I still don't believe that it is possible to break that, BTW. <img src="/forums/images/graemlins/pfft.gif" alt="" />

As for pulling that small bearing off the end of the mainshaft, is there clearance to get a tapered bearing separator in there?

Randii

Mmmmm - tapered bearing seperator .... Yep ... time to go to the tool store (again) honey! <img src="/forums/images/graemlins/rolleyes.gif" alt="" />



I still haven't managed to drag my disposable cameras down to the grocery store to have them developed <img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/smile.gif" alt="" />. Its tough getting Miss Ramie to trust me with the RSX given what I did to her this winter - BTW anyone know of a good site to buy an OEM front spoiler for an RSX?



I was going to mount half of the shaft on the "Carnage Award" and mount the other half on my "Wall of Shame" (am I the only one who has one of these?) But now, I think I'll have to forgo the Wall of Shame just so Randii can put it on his wall (*theme song running through my head* to dream the impossible dream ... ) <img src="/forums/images/graemlins/notooth.gif" alt="" />

Ever heard of 'Kimpossible?'

I dub thee...







Jimpossible.

It can't be done, Jim. <img src="/forums/images/graemlins/pfft.gif" alt="" />

Randii

Just remember you gotta bring that hunk-o-carnage award back next year so it can be passed on to the next parts breaker. I'd love to see that trophy get larger every year with more and more broken parts welded on.

Good luck Jim.

Dallas

Impact Wrench and a digital camera approx 15 miles away. All it takes is a phone call dude.