Finally Found A Tcase With Twin Sticks...now What Do I Remove

Rounding the corner on my T18 swap. Have the advance adapters shaft and adapter on the T18 and moving toward thinking about the tcase. I bought an older small index bore tcase that has the twin sticks and I plan on swapping them onto my large index bore 1971 dana 18. Question is what do I remove from the twin stick transfer case before I sell the carcass. Space is getting tight so I just want to remove what I need and sell the rest asap. I see the stick and front bearing retainer have to get swapped. Past that can anyone let me know what else I should remove so I can go from single stick to twin?

 

You'll need the front bearing retainer, shift levers and shift rails. Removing the shift rails requires complete disassembly of the transfer case.

There's a really good write up on taking down and rebuilding the Dana 18 out there. I think it was by Rick Stivers. Maybe on the 2A page and maybe it's here in the saved tech articles. A search of this site will likely find it for you.

 

what wheelie said
one note is to remove the front housing the 4WD rod must be in 4WD position
or the pill won't let you pull it off transfer case

 

I know I'm doing something wrong here but I don't know what. Shouldn't the front housing just slide off now?

 

I had that issue with a tcase once. The tolerance in the shift rod bores on the front housing is fairly tight. Try cleaning the protruding ends of the shift rods really good first; the built-up gunk on there will prevent the housing from sliding off over the shift rods.

 

Did you remove the poppet ball bearings from both sides of the two shafts? I see the access plug removed on one side, but if the bearingss are still in place it can still lock the shaft. Also, the pill also could be lodged between the shafts. You might have to let gravity help slide the pill to get the housing off.
One shaft stays in the main part of the case, while the other stays with the front housing. They both don't come off together with the front housing.
-Donny

 

I have both of the poppet springs and balls out of theyre homes. I'm almost positive its the pill holding me back but I'm not sure how to finaggle to get the pill to stop fighting? Alternatively could I just drive out the intermediate shaft and loosen the shift fork from the shift rail? That way I can tend to this issue on the bench instead of while wrestling the tcase.

 

Try rotating the shift rails 90 deg to move the detents to let the rails move past the balls

 

I think I am going to have to just drive out the idler and then disconnect the shift fork from the rail. I'm moving this setup to another case anyway so I will have to remove the shifter fork anyway. Once I get the front retainer off I hope having it in my vise will give me more room to get the two rails out (because I would like to remove the pill for 2wd low).