Series 3 transfer case front output housing

[jvsimmons]

I am trying to fix leaks coming from the transfer case on my 1983 S3 88 and I now find myself with a dilemma, which I am confident that someone else has also dealt with, and which may therefore offer some advice. This is my first experience working with a gearbox/TC so I also apologize if my questions are a bit "dumb"

All was going good ( fixing leaks on the rear output assembly) until I started to fix the leak between the front output housing and the TC. It appeared that the gasket was leaking or that the the leak was around the studs that secure the housing to the main body of the TC; or both. I thought naively that I could simply unbolt the output housing ( and the fixings) and slide it off - and putting it back would be the reverse. Unfortunately, this plan isn't working. I did manage to get the housing off. But it seems impossible to put it back and get the three shafts in the correct configuration. The main issue is that I cannot withdraw the transfer gear selector shaft from the TC. When sliding it forward it hits the edge of the bell housing - I need about a half inch more clearance to being able to slide it out. Is there a way to get this 1/2 inch? One idea would be to loosen the TC mounting bolts and try to wiggle the entire assembly just enough; but would I be able to get the front output housing on with the shafts in the right position? Has anyone made this repair without removing the TC? How?
OR, do I have to remove the TC from the main gear box and follow the instructions in the S3 repair manual on pages 167 to169?
Thanks,
Jim



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[jimrr]

you ,must have one clean rover!?! possibly you can put a bar on the case and move it enough to gain clearance but I'd be more inclined to spray some "spray gasket" in the gap where you can and put it back together. you're obviously very ambitious to try this but short of removing it all I'd quit while you're ahead. as for matching splines, all you have to worry about is the driveline splines, those are matched, look for the stamped dots. I don't recall whether or not the fork has to come out to get the dog gear detached. The S3 manuals (factory) have good diagrams and though you can short cut plenty of things some you can not.
the repair you're attempting is certainly non standard but maybe someone on here has tried that before, probably their first and last time?
Maybe the dog has slid off the end of the shaft as well if you can't put it back?

[jvsimmons]

UPDATE: Had to remove the transfer case to remove the front output housing. What I think I should have done (hindsight) is remove the seat box and lifted the front output housing out (speculating that that wopuld work). Also decided to replace the Fairey overdrive with a new Roamerdrive overdrive, and replace all the seals associated with the gearbox selector rods. So, got it all back together and before attaching the prop shafts I started the engine and tried to go thru the shifts. Found I had low range (and corresponding 4 wd while in low range). High range would engage and then pop out to the neutral position. I am supposing that I got something wrong inside the front output drive. Anyone have advice on this? Only thing I can suspect is that I somehow got one of the two plates that work between the selector rods in the wrong position. Help appreciated. Guess I better start removing the seat box.