Removing the Transfer Case Shifters

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=90 BGCOLOR="#006633" TEXT="#F7F7FF" bgproperties="fixed" background="079005a0ddvuru.png"> <div> <A HREF="http://www.vernco.com/index.htm" TARGET="_top" TITLE="http://www.vernco.com/index.htm"><U><B>home</B></U></A><B>     |     </B><FONT SIZE="5" COLOR="#FFCC66" FACE="Arial" ><B>Vern</B><B>co.com</B></FONT></div> <div> back to<B>  </B><A HREF="index.htm" TARGET="_top" TITLE="Tips and Tricks"><U><B>Tips and Tricks</B></U></A></div> <bR> <div> <A HREF="http://www.vernco.com/id173.htm" TARGET="_top" TITLE="http://www.vernco.com/id173.htm"><U><B>Site Map</B></U></A></div> <div> </div> </td> </tr><tr> <td valign="top" width=150 BGCOLOR="#669966" TEXT="#080000"> <div> <A HREF="id750.htm" TARGET="_top" TITLE="Easy Transmission Access"><U>Easy Transmission Access</U></A></div> <div> <B>Removing the Transfer Case Shifters</B></div> <div> <A HREF="id311.htm" TARGET="_top" TITLE="Pulling the Parking Brake Drum"><U>Pulling the Parking Brake Drum</U></A></div> <div> <A HREF="id317.htm" TARGET="_top" TITLE="Transfer Case Seals"><U>Transfer Case Seals</U></A></div> <div> <A HREF="id321.htm" TARGET="_top" TITLE="Remote Drivetrain Breather and Drain"><U>Remote Drivetrain Breather and Drain</U></A></div> <div> <A HREF="id337.htm" TARGET="_top" TITLE="TDC Finder"><U>TDC Finder</U></A></div> <div> <A HREF="id743.htm" TARGET="_top" TITLE="Timing Marks"><U>Timing Marks</U></A></div> <div> <A HREF="id328.htm" TARGET="_top" TITLE="Steering Bellcrank Pin"><U>Steering Bellcrank Pin</U></A></div> <div> <A HREF="id510.htm" TARGET="_top" TITLE="SemiQuick Steering Disconnect"><U>Semi-Quick Steering Disconnect</U></A></div> <div> <A HREF="id540.htm" TARGET="_top" TITLE="Windshield Latch Release Tool"><U>Windshield Latch Release Tool</U></A></div> <div> <A HREF="id397.htm" TARGET="_top" TITLE="Speedometer Lube"><U>Speedometer Lube</U></A></div> <div> <A HREF="id677.htm" TARGET="_top" TITLE="Driveline Calculator"><U>Driveline Calculator</U></A></div> <bR> </td> <td valign="top" height=390 BGCOLOR="#FFFFFF" TEXT="#080000"> <div> When removing the transfer case, one of the most frustrating parts is removing the shift levers.  Later CJ models had a removable panel allowing easy access to the shaft for the shift levers.  On my CJ-2A, the only way to reach the shaft is from underneath.  There is barely enough room to reach the shaft, let alone move it sideways.  Breaking the shaft free is very difficult.</div> <bR> <div> If removing the transfer case or transmission, you will have to remove the crossmember anyway.  If you loosen that first and lower the two units partially on a jack, you will have better access to the shaft.  Still, don't be surprised to find the shaft has seized in place.</div> <bR> <div> After removing the setscrew, soak the shaft with a good penetrating oil.  Despite what the label says, WD40 is a poor substitute, so get a good brand like Liquid Wrench or Kroil.  The anti-rattle clips apply a lot of side force, so pop them off the levers from above with a screwdriver.  I didn't have a spare set of anti-rattle clips for this front-view picture:</div> <bR> <div> <A HREF="id312.htm" TARGET="_top" TITLE="Zerk on Tcase shaft"><U><IMG SRC="48aaf4c0.jpg" border=0 width="175" height="76" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></U></A></div> <bR> <div> Here is the secret to getting the shaft to slide out.  Turn a wrench clockwise on the zerk on the shaft's end.  If you are lucky, the shaft will rotate as the zerk is turned.  If not, unscrew the zerk completely.   Find a bolt with the same threads as the zerk.  On mine, it was 1/4"-28.  Place the open side of a 1/2" socket (1/4" drive) against the end of the shaft.  Thread a bolt into the end of the shaft.  As you tighten the bolt, it will break the shaft free and pull it into the open end of the socket.  After the shaft first breaks free, you will probably have to remove the bolt and socket as the extra length will hit the floorboard.  If you then install a short bolt, you can grip that with pair of long needlenose pliers.:</div> <bR> <div> <A HREF="id313.htm" TARGET="_top" TITLE="Socket on Tcase shaft"><U><IMG SRC="48caf5a0.jpg" border=0 width="175" height="90" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></U></A></div> <bR> <div> One word of caution concerning the threads in the end of the shaft: Zerks typically use tapered pipe threads, so a straight bolt may tend to strip the threads as it is turned.  If there is any doubt, use a length of threaded rod and a nut instead of a bolt.  That way, no relative motion will take place under tension inside the female threads, making it less likely to strip the threads. </div> <bR> <bR> </td> </tr></table></body>