taking off the OD

I have to 2x Chuck's comment-it got extremely hot, hot enough to take the heat treating out. You might be able to replace the shaft and pinions but anything less, I wouldn't make any bets on the rebuild longevity. I have to ask was the oil scoop still attached-don't see it in pics? If so, about the only other thing that causes them to get that hot is insufficient lube in the TC.

 

Yes the oil scoop is there, it's not visible in the first pic but im holding on to it in the second pic with the rag. The T/c did leak oil and I checked it often but its possible it got low and the highway drive was just too much heat. It went out on the highway drive.

 

A highway drive and probably low oil is what took mine out years ago too... The oiling on them is very picky..

 

I think we found the culprit.. I dumped the oil from my drain pan I used for the t-case and tranny and there was nowhere near enough oil, maybe 2- quarts total. Originally I just pulled the plug and walked away while it drained, so I didnt know really how much came out. I think I better fix the leaky seals while its out. KEEP AN EYE ON YOU OIL LEVELS GUYS!!
thanks.

 

waiting on prices from herm, in the mean time im looking at replacing stock t/c gear and leaving OD off for now. The new gear is like $80.oo, I need the back t/c cover as well and it is $40.00. I hate to spend the 40 on the cover when it will be coming right back off when I can get the od fixed. Im being REAL cheap here, but could I just pull the shaft out of the od and whatever else needs to come out and just put the empty od housing on as a temporary cover??? Bad enough spending 80 on a temporary gear. I figure it will be on there for at least 6-months.

 

Money well spent IMO.
You'll keep the gear, nut, washer, and cover in your Jeep at all times, like most Jeepers do.
If the OD has problems again, these parts will be your ticket home.
Post a WTB in classifieds for used parts and pieces; state your spline and tooth count; something will turn up.

 

You have a very good point on keeping the parts in the jeep incase of future problems. I didn;t think of the cassified section here. Thanks for the tip, will do.

 

Herm probably has that stuff used also.

 

Herm got back with me.. the shaft is $125.00 and he said to take it apart and see if my spider gears are damaged, they are $57.00 a peice and there are 4 of them.. If it turns out to be just the shaft I need, that is close to the cost of a new t/c gear and back cover. I'll just fix the OD if thats the case. if the spiders are damaged then ill be looking for that gear and cover in the classified section for now.. thanks alot for your help guys.

 

I was in a similar situation. A friend of mine was rebuilding a Jeep and he told me that it had a PTO in it but he had no use for it and he'd sell it to me cheap but I had to replace the cover, etc. I found that I needed a cover and the output gear but I wasn't willing to pay $120 + shipping for them so I found someone that had some old parts and I bought a complete tranny and X-fer case for $20! I took the two parts out of that and I still have all the other parts for spares.

 

Regarding the cover for the hole in the back of the t-case, you can just use a steel plate. Mine came that way - the PO probably lost the stock cover and just cut out a flat plate. Works ok.

 

Jeepcj, I just discovered the exact same problem on my 66 that I recently bought with an overdrive. It wasn't getting any power to the driveline. I initially thought the clutch must be out. But after reading your thread I was convinced I would find the same problem with my OD. Sure enough, you can see the pictures below. All of the other gears in the OD appear to be in perfect condition. How did you finally repair your OD and did you learn anything that would be useful for me as I decide how to repair mine? Did your spider gears end up being ok? Thanks!

 

I couldnt afford to fix the OD right now. I took the OD off and located the stock tcase gear, cover and nut and put them in so I can drive the jeep but without the OD. YES, my spiders were damaged, take a real close look at yours. I thought mine looked ok until I really looked close, the very edges of the teeth were broke off. You can get that shaft from herm the OD guy. Im going to need a total rebuild when the time comes. I put a add in the clasified add's here for the stock gear and someone was kind enough to send it to me for the shipping rate. Been very busy and still need to send him that..

 

On my last Jeep, I had to use a slide hammer to pull the O.D. out.
P.O. had let the Xfer case run low on oil and, well you know!

 

I had a heck of a time pulling off the OD. No amount of prying was going to work. I ended up disassembling the OD, with the shaft still stuck in the spider gears. Then I screwed 1 1/2" bolts into the transfer case threaded holes, reassembled the OD, and proceeded to unscrew the bolts pushing the OD off of the spider gears. Here is a picture of the shaft stuck in the spider gears.

 

You got it all off didnt you? Mine was stuck in there pretty good too, I spent several days getting the shaft to come out.

 

Yea, I got it all out. I am going to do the same thing you did and replace the original gear so I can at least make it drivable.