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,