removing splined coupler from transfer case?

Does anyone have a clever technique/method for removing the splined coupler from the transfer case without damaging it?

 

Are you talking about the input shaft? Driveshaft yolk?

 

at the input shaft, yes - between transmission and Tcase. Normally stays with the case when it is removed from the transmission. I want a good method for pulling it off of the case without damaging it so I can design a spacer to go behind it.

 

What are you trying to do, swap it for one with a different spline count?

The input shaft is part one of the internal gears so you have to disassemble the entire thing to change it out.

 

I've put vise grips around the coupler then used a puller with the jaws reacting off of the vise grips, if that makes sense. Of course you can still do damage with the vise grips so you do have to be careful.

 

No, I just need to pull the coupler off to make a spacer to go behind it. I'm recentering it for my transfer case clocking ring, and need a good procedure for removing the coupler without damage (so no welding, etc. that folks do to pull it and discard it when going dual cases...)

 

has that worked for you? It seems like a press fit on that side...

 

Yeah, it's definitely on there and required the puller. Seems like people have had varying degrees of success with this method though. If you haven't already checked it out, there are some discussions about removing it in this thread https://www.tacomaworld.com/threads/official-crawlbox-bs-thread.422186/

 

My bad, I misunderstood

 

eh, my post was confusingly worded. all good.

 

You could possibly install a collar like below to get a bit more clamping force on the coupler and prevent marring then use it to react off of with a puller.

 

This style puller using two opposing of the four ujoint cap threaded holes on the flange. Get some long sockethead bolts and various washers, use something to protect shaft, like a small nut, warm it up. Replace seal while its out

 

uh - no flange.

 

Does it look like this? A three jaw puller will not grab it?

 

that's the front output flange; I need to separate the coupler that joins the transmission to the transfer case.

 

Never mind, I misunderstood, I thought we were talking output shaft. Damn Bynadryl....

 

This and a 3 jaw puller

 

What are you worried about .
The outside of the coupler is not used for anything . All you have to worry about is damaging the splines .
You can get a little agressive with the coupler
Got a reverse hammer on a clamshell puller ? Thats what I use to use
https://www.amazon.com/s?k=clamshel...=clamshell+puller,aps,181&ref=nb_sb_ss_i_2_16
There should be some info lower in this thread .
https://www.tacomaworld.com/threads/transfer-case-transfer-cases-in-first-and-2nd-gen-trucks.345652/

Maybe some info here as well .
https://www.tacomaworld.com/threads/transmission-swap-write-up-s.384303/

 

ah, so you use a bearing splitter with your puller? [EDIT] nevermind, I just looked up clamshell puller. nice but uber-expensive!