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Old 05-23-2010, 02:37 PM   #1 (permalink)
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Default Remove extension case w/o removing transmission?

Hey everyone.

I unbolted the extension case to the transmission w/ the transmission still bolted in. Can't seem to get it out. Shift forks, a gear is blocking the removal of the case.

Just wanted to know if it is possible to take this off w/o dropping the tranny. Has anyone doen this? And what is entailed?

And if I do have to drop the tranny, is it a whole lot of work?

Thanks
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Old 05-23-2010, 09:13 PM   #2 (permalink)
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It can be done, but it isn't really easier than dropping the tranny itself.

I bet you missed the 'hidden' bolt...



It is the reverse shift rim bolt. Here is a link to a rebuild article that could give you a little insight to what you are looking at.

Tranny Rebuild
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Old 05-23-2010, 09:21 PM   #3 (permalink)
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read the article beforehand. got the bolt decided to pull the transmission. having trouble, since i'm doing it by myself dropping it. I've got a regular jack, but its not cutting it.

any suggestions?
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Old 05-23-2010, 09:34 PM   #4 (permalink)
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I have always put the rig up on ramps so I had plenty of room under the rig to move around and wiggle the tranny on the way out.
After making sure everything is disconnected, including completely removing front driveshaft and the jackshaft (small tranny to t-case).
Another trick is to trim the rear tranny crossmember plate. I have trimmed mine up to 3/4". Just make sure you leave enough meat to hold the mount without tearing out under load.
I would get underneath it and wiggle it until it comes out. Sometimes you have to be inventive as you lift the rear case up to the floor. Sometimes turning the tranny a little will get you past the obstructions.

Hope that helps a bit.
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Old 06-09-2010, 08:29 AM   #5 (permalink)
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Just wanting to clarify a couple things since I got a tranny jack today

I'm removing the tranny, but only replacing the end casing. Are there gears housed in there that I'm going to have to remove to put in the new end casing?

If so, is this a pain, or easy? Any specific tools I need?

Just wondering since I though removing the end casing was going to be a breeze and is turning into a pain...

Thanks!
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Old 06-09-2010, 10:18 AM   #6 (permalink)
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I found it easier to drop the whole transmission and work on it. It's a lot easier to get to the stuff on top and you can move around it and see down in it at different angles. My floor jack was getting in the way so I just lifted it out by hand. If your a small person it may be hard to bench-press the case but an average size man can handle it. If you have a special tranny jack I suppose that makes it a lot easier. What's a tranny jack look like?
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Old 06-09-2010, 11:58 AM   #7 (permalink)
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just like a floor jack, except with rods on the end to fit into the tranny

...so theres no gears/ rods in the end casing that I'm going to have to pry out?
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Old 06-09-2010, 12:35 PM   #8 (permalink)
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here's the best pic I can find for you as far as what you're going to see when it comes apart.

http://johnny-inc.com/Samurai/Tranny.../Extension.JPG
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