Hope you can help me with lower transfer case bolt

Hi Guys,

I am working on replacing my clutch today. Unfortunately, I cannot get the bolt on the lower gear off (see picture). I have read several posts, birdman's clutch guide, YouTube video's, etc., so I understand that the nut is supposed to be super tight. However, yesterday I managed to break the end of my breaker bar off (it was not a very large one, but still...).

Today I used my 250 ft.lb torque wrench and it still won't budge. I leaned on it with all my weight (225 lbs.) and it won't move one bit. Any suggestions????? I don't know where to go from here.

Any advise is welcome.

(Sorry, the image is rotated 90 degrees, but the situation is clear)
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First suggestion is dont use your torque wrench as a breaker bar. Just get a big one from sears.

Doesn't that bolt have reversed threads?


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Is that the input shaft ? The one that splined to clutch or transmission?

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I got a new breaker bar and after much effort (putting all my weight on it again and pushing as hard as i could), it came loose with an incredibly loud BANG!!!! whomever was in there before must have torqued it way too high (certainly more than the 145 lb-ft it's supposed to be). I though at first that I broke something, but all is ok upon inspection. Thank you for your suggestions.

Jan

 

Just did that myself using an impact wrench... got a harbor freight nearby?

 

And/or somebody put a Locktite on the thread.

 

Tried that too. Even with impact wrench it wouldn't loosen at all.

 

Mike, fortunately not. It was just crazy tight. At least it's off now and I will go forward with the clutch replacemtent

 

Get the proper Hill/Ferrari socket tool and give it a solid blast with an impact wrench. Loctite or not, an air tool should easily break it loose. Do not use a torque wrench as a breaker bar, in general.

 

Worth changing the seals (behind that gear's bearing, and the crank seal) and the pilot bearing (62202) while in there. I got a Tribco kevlar rebuild of my disk and the flywheel/pressure-plate ground for $300 by my local clutch shop. A couple of people I know have them and really like the feel (plus they last longer.)
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What kind of impact wrench? Not all impacts are the same.

 

Crank up the air pressure


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The torque was well over 250 lb-ft. Even at 100+ psi my impact wrench won't get there.
Anyway, I got it off with the large bar.

 

Thank you for the advise! I will replace all the seals.

 

After the crazy tight ring nut on the transmission input shaft, I'm now having trouble removing the bearing. It won't come loose as described in birdman's tutorial. I read on a technical thread on this forum that the spacer and snap ring behind this bearing will pass through the casing when pulling the bell housing on a QV. Can anyone confirm this? In that case I can pull the housing off without worrying about the bearing.

I'm not very thrilled with the idea of pulling the bell housing 1" apart by using a steel puller as suggested by birdman. I would think that it would put stress on the other shaft and struts (as it will pull crooked) is it the only way to sufficiently break the seal?

 

If you are talking about the lower drop gear bearing. I just start to pry the bell housing in several spots and it pops out. Make certain all the bell housing nuts are off. That being said there are 3 variations of the 2206 bearing, if bearing is original the method I mentioned worked for me several times. Then the spacer ring and clip pass through the center of the 2206 bearing.

 

Thanks, I got the bell housing and the bearing loose. Now I'm having a hard time getting the ring/spacer off the shaft. It's on very tight. I'm becomeing frustrated because all the parts which supposedly come off easy, are very tight on my car...