Intermediate Shaft

Quick question...will the intermediate shaft on a D18 come out the front of the case or does it have to go out the back?

 

Use a soft drift to drive the intermediate shaft out (towards the rear of the case). Shaft is larger on rear, driving out forward will damage the case. Remove intermediate gear, thrust washers, bearings from case.

borrowed from: The Novak Guide to Rebuilding the Jeep / IH Dana 18 Transfer Case (novak-adapt.com)

 

Out the back. The area where the retaining slot is at is a slightly larger diameter on most.

 

Actually this is all your fault! LOL
I read your thread about the crappy Crown transfer case spacers and washers, and I decided to take mine back apart enough to inspect those (I just installed a Novak shaft and bearings in it)
I thought it would be quick and easy to pull that out real quick but I forgot about the Ebrake drum. I'm not really excited about having to pull the rear yoke and drum off and having to reseal all that.

 

I suggest drive it for 100+ miles and be extra aware of any strange noises.
I did this same overhaul about 7 years ago (6500 miles) and haven't had any trouble.

 

Listen for strange noises, use a magnetic drain plug, keep tabs on operating temperature. you might be able to kinda sorta measure and feel from the bottom drain pan. i'ld personally feel better breaking in without the overdrive if you have one installed.

 

I have a used shaft I cut off the length of the gear, you can put it all together and push the cut off shaft out with the new shaft and not lose all your rollers. If you want to use it I will send it to you. worked good for my rebuild. Call me at 734 776 7659.

 

I've got one I made out of a 1 1/4 dowel rod.
Thanks for the offer!

 

No problem, worked good for me. Good Luck, Doug. I don't know if you know to put sealer on the parking brake drum spline. I didn't and got oil on my new parking brake. Had to take it apart clean it all and put it back together, locks up now good.