Clutch Slips Badly After Re-assembly?

Ok, I am stumped. Re-assembled the transmission, transfer case, clutch, etc. Now it appears that the clutch simply does not engage correctly and slips badly. I can rotate the engine by hand with the tranny in gear, transfer case in low. One can feel something slipping, the front axle is immobilized as is the rear. What the heck is going on? What else could be slipping and if clutch, why? There is free play in the pedal linkage and I can press & release the clutch pedal and watch the clutch move.

 

OK, not the clutch. Somewhere between the engine out and the output of the transfer case there is slipping. I am trying to remove the front crankshaft pulley nut, and immobilizing the engine, so far, no success.

 

are you sure the transfer case is not in neutral

 

I see the single shifter linkage in the pic, but I'm not familiar enough with what part is out and in when in neutral. One of you guys knows.

 

I have put transfer case in 2wd high, neutral & 4wd low & high. The front axle drive does indeed engage, but I cannot seen to engage the rear axle drive. It simply acts like it is disconnected. All I want to do is get the flippin' nut off the crankshaft pulley, and I cannot find a way to hold the engine crankshaft. This does have an overdrive on it, would that cause this?

 

You should be able to accomplish your task of removing the crank nut by engaging 4 wheel drive (single lever pulled to the second or fourth position away from the firewall), and putting the transmission in any gear. Chock a tire or two, and go to work on the nut on the engine. The drivetrain should hold things from turning.
-Donny

 

Sounds like something in transfer case or overdrive to me.

 

Put a big pipe wrench on the front axle U-joint to hold it steady and remove nut on pulley.

 

Walt's idea worked. Turns out the overdrive was not engaged as I thought, so the engine would spin. I even worked the linkage back & forth, but it was not quite there. Kinda thought the overdrive wouldn't matter, and in either mode would engage. Thanks for the comments.

 

Good show.

 

Yep, Warn hubs. I have gone through pretty much everything, although I have not spent lots of time making things pretty...Next is fuel system, then heater & finish dash. Hope to get it running before the snow flies.