Dana 18 Transfer Case -- Front Cap Stuck

Rebuilding my '59 CJ5. Trans/transfer case is the last (and most aggrevating) part to be restored. It has been a long time since I messed with a tranny so I'm in new territory here.

After finally getting the front yoke off (two guys, heat, impact wrench and a lot of muscle) yesterday, this morning I started to tear down the transfer case.

The front cap is stuck part way off, about 1/2 inch out and will not move any further, nor will it go back to the original seated position. Seems to be stuck on the hi-lo shift rod (that's the long one that goes into the xfer case). I assumed the cap would slip off the shift rods, but that does not seem to be the case.

The manuals I have say the intermediate gear has to come out first. I did not do this as I could not see how that would keep the cap from coming off, and I do not want to mess with getting the needle bearings back in place if I can avoid it. I'm not rebuiding the tranny, just replacing seals and gaskets.

Does the intermediate gear have to come out so you can get at the shift fork to loosen the set screw? If that's the case, then that's the route I'll take. Have I missed something that will keep the front cap from coming off?

Any advice would be very much appreciated. I would include pics, but camera interface to the 'puter is on the fritz.

 

Don't know if this will help, but there's an exploded view of the D18 here:http://www.film.queensu.ca/CJ3B/Photos/Parts/TransferCase.gif:v6:

 

I just finished (firefightermikes) dana 18. No you do not need the intermediate gear out to remove the front case. The clearance inside the shift rail housing is close and if your rod has a burr on it it will more than likely keep it from sliding thru. Check the placement of the shift rods as far as the 2wd/4wd, the interlock pill may be snagged between the rods and causing them to bind up and holding the housing in place. The intermediate gear is the 1st thing I put in when rebuilding them so no you can take the whole case apart and leave that for last if you want. Try taking the ball and spring detents out of the front housing and see if it helps.

 

There are two caps on either side of the housing that hold a spring and a ball. They are what lock the shift rail into place when they enter the rail detent when shifting from 2WD to 4WD or High to Low Range. Have you removed these? They’re items #17,18 and 19 in grannyscj’s exploded view, but the diagram is a little misleading since they are just below the shift levers pivot and on the left and right side right where the shift rails go through.
It sounds like you may be hang’n up on these.

 

Heh, beat me to it.
BTW, the interlock pill he’s talk’n ‘bout is item #20 in the diagram. It’s what keeps you from shifting into low range until your in 4WD. Very well could be hang’n up on that also.
When I rebuilt mine, it was something I left out so I can use low range in 2WD.

 

The interlock pill has to be the culprit. I had already removed the poppit balls and springs, but missed the fact that the interlock was there also.
I looked at the D18 tonight, additional question to make sure I'm reading this right.
Should the interlock actually slide out one side or the other? I doubt it, can't see how.
So that leaves jiggling the shaft(s) until the interlock moves to a position to allow removal. I tinker some more tomorrow.
Thanks for the advice.

 

It worked... got it loose. With a little persuasion from a ball peen and wood block I got the front cap back to it's seated position. Once the hi-lo shift rod was fully back it darn near fell apart.
The interlock is one part that will not be reinstalled.
Thanks to all for the help.