Trying To Fix A Leak - Now Stumped

I've been trying to fix a leak in my transfer case and I've identified 3 sources:

1. Bottom cover
2. Rear output bearing cover
3. Front output bearing cover and shaft seal

Since I'm removing the rear output yoke anyway I'm replacing the shaft seal as well.

First two came off and are cleaned up ready to be re-installed. But the front output bearing cover will not come off. The FSM says to remove the yoke and seal, set the lever forward (I then removed it to make room), remove the poppets and springs, then slide it forward. Left is front in the photo (breather removed).

It went about 1/4 inch, then stopped. Now won't go forward or backward. 3 hours of trying to nudge it and nothing.

What do I need to do to finish this one? I don't want to remove the TC, simply because that means also removing the PTO, neither of those junctions leak, so I feel it's adding steps I didn't think I needed. The only good thing is the Old Girl is in the garage as she's not a roller right now.

 

you need to shift it into 4WD . also remove shifter ball and springs from both rails . to remove front housing

 

Try turning the output yoke while trying to move the lever.

 

I did remove the springs and balls. But the instruction said "4WD lever forward" which is 2WD hi on a single stick.

So 4WD -- low, hi, or does it matter?

 

Yoke is removed, but shaft will not rotate. I tried temporarily putting the yoke on to get better leverage, but no joy.

 

pull out 4WD rod only . the inter lock is what's keeping it from coming off

 

I'm being a bit thick

I'm being a bit thick...which rod is the 4WD rod?

Edit: studying both your photos and my photo I think I've figured it out...but won't know until tomorrow...too late and I'm beat.

I think that interlock pin shifted on me, and the whole assembly is sort of locked into place.

 

one close to transmission - left

 

You can sometimes change seals by driving a junk screwdriver or a cold chisel into the seal and prying it out. I have also heard of people screwing in a couple drywall screws and using them to pry out the seals

 

let me try and explain the lock out pill
there is one indent on inside of each shift rod . with the pill floating in housing between both shafts
the pill has to fall into indent on 4WD shaft in order to shift to low range
I think what is happening with you is the pill is now stuck in between both shafts and locking up housing
1'st picture is 2WD

Do you see where location and position of pill . the H - L will not move till it's in 4WD

transfer case is now in 4WD high . the pill is in spot with indent on both shafts . this is where the housing would just pull off
I am thinking you will have to tap both shafts back in till the housing is flush again . then pull out on 4WD shaft only . that single stick linkage has to come off . H - L shift rod stays in transfer case

 

I don't even have a dog in this fight but that is an awesome description of how this works. Thanks for taking the time to do this.

 

That's brilliant! It's off, great advice. I did have to tap it a bit, I was visualizing what it needed and while still a bit difficult it did sort of slide off.

Cleaning it all up now so I can reinstall.

Thanks much!