series transfer box problems

I'm trying to strip down my transfer box but i'm bu99ered if i can get the intermediate shaft to move, any hints or ideas or is there anything obvious i could be missing?
Pics would be helpful!

Simon

stt said:

I'm trying to strip down my transfer box but i'm bu99ered if i can get the intermediate shaft to move, any hints or ideas or is there anything obvious i could be missing?
Pics would be helpful!

Simon

Click to expand...

remove nut/washer holding retaining plate for inter shaft on t/f box (if you ghavent already!). rtemove rear mainshaft bearing housing. Pull out inter shaft. Think there is a special tool that grips it but big screwdriver and a thump will usually do it.

tried that - but it wont budge, i've even now managed to break the lip off the casting on the end of the shaft that the retaining plate locates in!

stt said:

tried that - but it wont budge, i've even now managed to break the lip off the casting on the end of the shaft that the retaining plate locates in!

Click to expand...

Does the intermediate gear spin on the shaft? (It should) or is it seized on.

If there isnt enough lip to get a grip of, the only other option is to tap a hole in centre of shaft (cant remember if there is one already there?) and use a bolt and large washers that "go over" the end of the shaft. Tighten up the bolt and it should extract the shaft.

you have removed retaining plate in pic
Can you check the intermediate gear turns/slides on shaft ok , if so it can only be siezed in the ally casing perhaps with corrosion, this weather the ally will shrink on a bit tighter, you could try a blow torch or stick it in the oven when the missus is out it should come out fairly easily with hammer and sodt drift

finally got it out, had to weld a washer onto the end of the shaft and the use a puller on it - it means the box is now dismantled, but i need a new shaft!