T-case Intermediate Shaft

I read somewhere that you can r&r the intermediate shaft in a D18 t-case without pulling the case out. Just wondering if anyone here has done that and if it is relatively straight forward. I may have to replace my intermediate shaft (again) and I really don't have time to pull and re-install the t-case. If I didn't have the overdrive I'd probably just pull the case, but I sure don't enjoy round-tripping the OD, especially if I don't have to.

 

I did it several years ago in my willys truck. My t-case is the d-18 with the 1/4 shaft and individual rollers, and used Vaseline to hold them in place. Took me around a hour and a half lying on my back in the back yard.

 

Thanks lamar, that's reassuring. As often as I have laid out under the Jeep, I never really looked at the feasibility of doing the shaft without pulling the t-case. I may have another issue too. I replaced this shaft about 2 summers ago. The old one was galled pretty bad and it only made noise in low range. Today it started making the same noise, only in low. It's kind of a rhythmic grinding. Guess I'll know in a day or so.

 

Depends on what transmission you have. A T-90 or similar shouldn't be too much an issue. Some transmissions can limit access to the intermediate shaft.


Sent from my iPhone

 

Thanks Nick. I'll know today after I check it out, but I'll bet the T18 I have is one of those trannys.

 

If it is the stock intermediate shaft that comes out from the rear and has no keeper on the front, it shouldn't matter which transmission it is. Biggest problem is just keeping the needles and washers in place while assembling but not a difficult task.

 

I replaced the intermediate shaft, bearings and seals in mine without dropping the transfer case.
It takes a little bit of touch with the loose bearings, but it can be done fairly easy..

 

In the almost 20 years I've owned this Jeep I have rebuilt the t-case twice and done another D18 for my business partner. I've always used a dummy shaft to install the intermediate shaft. That's not an option in this case. I do have a shot at the front end of the shaft so I can drive it out the back. I won't be able to use a shaft with the o-ring though as I can't drive the shaft in far enough to put the o-ring on and drive it back in. Also, this shaft that I'm replacing is only 2 years old. We're talking no more than a couple thousand miles. If I can find the specs for the ID of the intermediate gearset I'll measure that to make sure it's within tolerance. Short of that being out, I'd have to say I got a defective shaft. When I replaced the shaft in 2011, visually the bore on the gearset looked fine. It was smooth and clean. That doesn't necessarily mean it's within spec though.

Shout out to Nick: Do you have the spec for the ID on the Intermediate gearset? It's not in my FSM.

Here's a pic of the shaft I replaced in 2011. It was in for at least 8+ years.

 

Posi, Where did you get that shaft?..........Might have to pull it now?

 

So, I've decided to do the AA tapered bearing conversion. I'm buying a kit from sdcj6 that he had in his Jeep for awhile. He's using a D300 now. Tomorrow I'm making one last trip out to the Rubicon to install the last 8 waterbar markers. When I get back it's off to the carwash to clean the Jeep, engine and drivetrain. Then it's in to the garage and start taking it apart. Supposed to get snow here Tuesday, so I'm right on schedule.

 

No problem, Chuck. I'll take some pics of what I have to do to get it to fit. Looks like I'll have to clearance the Novak adapter a little. Other than that, shouldn't be a big deal.

 

I had intentions of starting to pull the t-case today, but with a high temp of 23* I couldn't be persuaded to go out to the garage.

 

Getting soft John ?

 

Yep, old too. I'll dig out the insulated Carhardts tomorrow and make some progress. Especially since we aren't forecast to get above freezing until next Tues. I do have a space heater in there I can fire up.

 

I know how you feel. I have been putting off changing a headlight on my car because it's too cold outside.... I can't even imagine how some of our friends in the really cold regions deal with it.

 

I put a lot of effort into insulating and heating my garage. I have two of these Dayton electric heaters:

 

I couldn't view the pic Warloch.
Tim: Someday when I grow up I'll have real heat in my garage! Is that electric? Efficient? 110 or 220v?