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post #1 of (permalink) Old 03-17-2003, 12:19 AM Thread Starter
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Weekend pics & Detailed t-case dissassembly pics

Got some more work done on my truck this weekend. Longzuk was there and did a 3" body lift on his samurai. I wasn't able to finish off my toyota axle swap or mount my t-case without a welder (out of gas) so I disassembled a t-case.

pictures: (click to enlarge).

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_115705aa.jpg">

before the body lift:
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_124543aa.jpg">

cutting perches
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_125818aa.jpg">

body lift blocks
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_125925aa.jpg">

longzuk stuck in the snow
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_134232aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_134814aa.jpg">

perches fit
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_140535aa.jpg">

Toyota axle swap under way
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_152703aa.jpg">

longzuk's body lift installed
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_153240aa.jpg">

stuck Suzuki Vitara
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_153612aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_153637aa.jpg">

removing perches from toyota axle
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_163630aa.jpg">

grinded smooth
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_171735aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_172647aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_172806aa.jpg">

assembled rear axle
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_180918aa.jpg">

T-case disassembly begins
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_191021aa.jpg">

Remove flanges
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_191333aa.jpg">

Pull out speedometer gear
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_192515aa.jpg">

Remove front case bolts
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_193734aa.jpg">

Remove front case
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_193924aa.jpg">

Hammer out front output shaft from front case
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_194115aa.jpg">

Remove center case bolts
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_200002aa.jpg">

I broke a lug off the case while splitting the center and rear case.. no big deal.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_200401aa.jpg">

Remove rear case from center case.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_200849aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_201301aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_201306aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_201314aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_201323aa.jpg">

Remove bolt located above shifter shaft. Be careful not to loose the spring and ball that comes out
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_201750aa.jpg">

Hammer pins out of shifter forks using a punch to seperate forks from shifter shafts.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_203644aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_203656aa.jpg">

Removal of the 4wd/2wd shifter shaft may require a hammer and punch. Be very careful when removing this part, as 2 ball bearings will pop out of one of the 2 holes for the shifter shafts (in the center case). A spring will also come out.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_205346aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_205842aa.jpg">

shifter shaft parts that will come out of the hole(s)
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_210244aa.jpg">

shifter forks and shafts removed
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_210619aa.jpg">

remove input shaft, counter gear and output shaft from center case.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_210805aa.jpg">

Counter gear bearings, shims, and spacer.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_211445aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_211932aa.jpg">

output shaft
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_213104aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_213116aa.jpg">

Remove output shaft rear bearing and retainer together using a puller.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_213456aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_214055aa.jpg">

Puller required to remove speedometer gear and thrust washer. I pulled on the low output gear, worked fine.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_214649aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_215043aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_220408aa.jpg">

Remove snap ring on the front of ouput shaft, and pull off gear that is used to engage the front ouput shaft with the main output shaft.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_220529aa.jpg">

Use a puller to remove ouput shaft front bearing.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_221037aa.jpg">

Output shaft completely disassembled.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_221622aa.jpg">

<a href="http://home.off-road.com/~asheng/03.16.03/2003_0315_221632aa.jpg">

Stock high output gear on the left, GRSII output gear on the right.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_132208aa.jpg">

Stock counter gear of the left, GRSII counter gear on the right.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_132750aa.jpg">

Use a puller to remove the rear bearing off input shaft. A different kind of bearing remover will be necessary to remove the front bearing as there is no room between the gear and the bearing for the puller jaws.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_133339aa.jpg">

Stock input shaft on the left, GRSII input shaft on the right
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_135120aa.jpg">

Stock gear set on the top, GRSII gear set on the bottom.
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_135630aa.jpg">

Organized parts
<a href="http://home.off-road.com/~asheng/03.16.03/2003_0316_141152aa.jpg">


Hopefully these detailed t-case disassembly instructions and pictures can be useful to someone. I'll have more pictures and information once I sandblast and paint parts, and install my GRSII. I'll finish my toyota axle swap in another week or two so I'll have pictures and a detailed writeup of that too.

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post #2 of (permalink) Old 03-18-2003, 09:35 PM
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Re: Weekend pics & Detailed t-case dissassembly pics

thx for postin the pics for me anton didn;t think the body lift would make that much difference.

Sean [img]images/graemlins/40BEER.gif[/img]
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