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KZJ78 Transfer case rear output shaft bearing

graysworld

Active Member
Joined
May 27, 2015
Messages
98
After replacing the whole front-end wheel bearings etc, I still have the rumbling that I thought was the wheel bearings. So now I think it is the rear transfer case output shaft bearing. I have removed the rear prop shaft and the noise has gone. I can move the prop shaft flange at the gearbox end up and down! I will replace the prop shaft universal joints as a matter of course. My question is…is it possible to replace the bearing with the gearbox in the car? Or do I need to remove it and strip it down? Maybe I need to get it done by a gearbox specialist? Can anyone recommend one in the south of England? Any advice gratefully received

Graeme
 
Thanks Tom, I guess I should be more specific as I am based in Dorset so Sussex and Kent are a bit too far.

Regards Graeme
 
A little write up on rebuilding the transfer case. Firstly, I must Thank Otramms YouTube channel for a very informative rebuild video. OTRAMM VIDEO. Although I have an automatic gearbox it is almost the same procedure. Along with the workshop manual this was a great help. I did the job in-situ as working alone on my drive I would not have been able to remove both gearboxes. I bought a rebuild kit from Terrain Tamer. Very good service. I bought some assembly Goo which helps to lubricate everything during start up. It is also good for sticking the outer thrust washer in place whilst fitting the outer casing. One mistake I did make was not putting the clamp on the low-high selector before putting the outer casing on. This resulted in it falling inside and me having to remove the case and refitting. Fitting of the said casing is as Otramm say the only fiddly bit. It is awkward working under the car, but I drove it up on ramps at the front and jacked it up and supported the rear on chassis stands. Bearings from the gearbox input shaft and the rear output shaft need to be pressed off and on. The only bearings not in the Terrain Tamer kit are the split needle roller bearings inside the output shaft. These are not really needed as they do virtually no work. I now need to replace the prop shaft universal joints and refit. Also sort out the exhaust puzzle! As has been mentioned it is a real pain. I managed to take it off, but I cannot get it back on. I am going to cut it and fabricate a joint to overcome the poor design. I will post a photo when I have finished.
 
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