Separating Tansfer Case from the Transmission

[east high]

It's the part you have circled in your photo.

[SafeAirOne]

What is the castelated main shaft lock nut that I need to go at?

It's that thing that you are pointing to in your pic. It's just like any other ordinary nut except that it requires a different socket (or a punch/drift) to install or remove it.

[Les Parker]

This is the special tool :-

http://landroverparts.roversnorth.com/Products.aspx?model=rnt0002

Though to just remove the gearbox away from the T. box it's not necessary to remove it.

Just the 3 nuts hidden by the intermediate gear.

[SafeAirOne]

Though to just remove the gearbox away from the T. box it's not necessary to remove it.

Just the 3 nuts hidden by the intermediate gear.

...which won't correctly fit any socket in your toolbox, though one can be made to work.

[amcordo]

...which won't correctly fit any socket in your toolbox, though one can be made to work.

Of course.

[amcordo]

OK, I'm being high maintenance about this thing. So I'm to the point where I have to pull the shaft from the intermediate gear. I've removed the little bolt and plate that hold it in, but all I have is a simple pitman arm puller. I'm not having luck using a lever and fulcrum to remove the shaft, so can someone tell me what sprocket puller I should get for this?

[SafeAirOne]

Make sure the vehicle is chocked and everything is in neutral and there's no force on the gears. That shaft will just fulcrum right out. There's nothing holding it in there really (except the external keeper that you presumably removed already).

Be prepared to catch the gear and bearings that will fall out with the shaft removed.

[amcordo]

The transfercase/transmission are out of the vehicle and on the floor. The gears move freely.

I tried to fulcrum it out using a pry bar and the handle from my pump jack, but it is just not budging. (that keeper tab is off). I still haven't removed the output shaft yet, but maybe I'll start on that to lessen the frustration.

[I Leak Oil]

Give the end of the intermediate shaft a couple swift raps with a soft hammer (brass) then try to pry it out again. You can also try prying it and tapping the end with a hammer at the same time. Once it frees up it should slide right out. Along with catching the bearings and gears, there will be thrust washers that come out with them. Make note of what end each set comes from and reassemble them in the same place.

[amcordo]

Closing this thread:

Found the biggest pry bar I could get at a Home Depot, had someone brace the transfer case to stop it from moving, then used the hooked side of the pry bar to put pressure on one side, and then on the other. popped free and slide out by hand after I put everything into it. Wow.

[SafeAirOne]

At least it wasn't leaking at the joint.