Tips, traps, tricks? Rebuilding transfer box.

[luigi]

I am about to put a bearing kit in my transfer box.I have the box apart on the bench and hope to get the bearing kit tomorrow. I am now thinking that it might have been a better idea to get someone else to do it. But I have reached the point of no return. I think a bit of experience would be a great help in this job. Can anyone tell me, how to get the collar off the main shaft. The one that holds a ball bearing and the speedo drive. Do I attack it with an angle grinder, like the collar on the wheel bearing?
There must be lots of tricks that people have learned from experience. And lots of traps for new players as well. Again sorry to cover old ground, but some advice would be appreciated. Thanks in advance.

[steve125]

no need for a grinder, everything should be able to be removed with a press or if you are really dodgy, some lumps of wood and a big hammer.

the instructions for installing gears are very helpful in disassembly/reassembly of the transfer case.

http://www.trail-gear.com/pdf/suzuk-tcase.pdf

[luigi]

Thank you Steve125. Brilliant, just what I needed. I have the use of a good press. Thank you.

[jonfromhamilton]

Be extremele careful when removing ball beartings and springs that you remember where they came from otherwise you will be like me, feeling bad.

[luigi]

We learn our best lessons from our biggest mistakes.

[gwagensteve]

Be extremele careful when removing ball beartings and springs that you remember where they came from otherwise you will be like me, feeling bad.

Those little ball bearings can roll a long way too....

Steve

[luigi]

Try looking in the workshop vac.

[jonfromhamilton]

I found a good place to find ball bearings.
Steve's shed.

[Matthew]

Did we loose a bb when dismantling?

[gwagensteve]

It seems the 4WD light ball was lost. I had one- they are larger than the detent balls. (Detent approx 8mm, 4WD light 9.5mm)

Steve.