Topic: front output seal...............and now some other questions!!!

[dntsdad]

Doing my first transfer case work (duals) and replacing the seals along the way. I went into Marlin's and picked up new seals for the front and rear outputs but the front one has me scratching my head. I understand the seal then the felt and then the metal cup to hold the felt. My question is.......is the metal ring a reusable part? I do not have a socket that large to drive it out, and a screwdriver is just going to bend the hell out of it. Is there a trick to removing the cup and without destroying it?

Thanks in advance.

Jason

[2manytoys]

http://board.marlincrawler.com/index.php?PHPSESSID=5ccc30d0057a9e10c30a65052ab51ec0&topic=73807.msg887907#new

Not sure if I did the link right but it's in the product support section. It mentions using Marlin's T-case output eco seals. The rear one can be used on the front if you do somthing with the dust shield. Maybe this info answers your question.

[dntsdad [OP]]

ya I had heard that before, but the guys in the shop said to use the seal, felt, cup method instead. It was better protection.

I am just stumped to see if I am wasting my time trying to save this metal cup, or what is the best method to get it out.

Thanks

[ninja turtle]

ya you need to reuse that metal cup. i have a seal driver kit with a bunch of different sizes, it was about 15-20 bucks at napa.

[dntsdad [OP]]

Ok. I will look into that.

One more thing but a little background. I have a stock 2.28 case (not sure of year) and another case that I bought used with Marlin 4.7's already installed. I have ripped apart both cases. The 2.28 to make a crawl box and the 4.7 case because there was oil on the outside and I assumed that it was leaking so I wanted to reseal everything before installing everything. Using MC-07 and twin sticks in the rear case.

In the tray that the 2.28 case was disassembled I have this spring.


I dont seem to have that in the 4.7 case. Is this a problem?
I cannot find a part diagram for the transfer cases so I am unsure of the purpose of this spring and of course I dont remember it coming out.

Hopefully this is something that the 4.7 eliminated by adding the gears.

Again, thanks for the help as this is uncharted territory for me.

[ninja turtle]

i think thats a detent ball spring. its pushes a b.b. into the little notches in the shift forks.

[dntsdad [OP]]

Got the cup out. I used the cupped end of  a holesaw and hit the teeth side with a piece of wood covering them. The seal and the cup came right out.

I dont think thats the detent ball spring. those are much more tightly wound and more cylindrical shaped, and there are two of them. there is only one of these.

[ninja turtle]

nice. i remember now how i did it the first time, i used a piece of abs pipe.

ya, your right about the spring. dunno.

[dntsdad [OP]]

Getting to the point of welding the fork. Does this look right? Weld the ends of the stock to the fork so everything sits flat?

Seems simple, but no going back if I screw this up so want to make sure. Most of the pics I find are for forward shift so they dont apply.

[ninja turtle]

[OOPS]

In case you do not have it, here is a link to the FSM section of the 85 gear drive T-Case.

http://www.lukemiller.org/toys/1985_toyota_4cyl_transfer_case_FSM.pdf

[dntsdad [OP]]

thanks guys