Transfer Case Rebuild...
added 3/27/98
Well, almost silence. The transfer case was functioning as
it should and not leaking anything, but it was making a
whining noise in 2hi and 4 hi, but not 4lo. Petroworks to
the rescue with a rebuild kit for $180.
To my surprise, the rebuild was not all that difficult. I
had to buy a 7-ton gear puller from Sears (but honey, I
NEEEED it!), and have a hollow cylindrical drift made for $25
at the local machine shop to re-install the bearings. A
beefy steering wheel puller and some heat were needed to get
the drive flanges off the shafts as well. The only real
tricky part was having the case and shafts measured for
installation of the proper shims. Again, the
local machine shop was able to help me out.
Tip: The Samurai transfer case is MUCH easier to
extract/install if you remove the case’s shift lever first,
and stuff a rag in the hole. Remember to make sure the case
is in neutral before you pull the lever out though.
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