Separating transmission from T-case

[Beanz2]

Guys,

I'm caught in a real bind trying to get this R151F tranny home (got it from Mike S. on this board. Thanks!). I separated the transfer case and GRB. The remaining transmission has the gearbox and what I call the "shifter box", which is the part that attaches to the GRB. (This is where the shifters come out from. )
The gearbox-shifter box combo weighs 102 lbs, which is 2 lbs. above what Greyhound or American Air (my flight tomorrow) would accept.

I figure I need to break the pieces down so I can check it in as luggage. The weight limit for checked in baggage is 70 lbs. But how do I separate them? The pieces move apart just about 1/4" but no more. Is there any internal bolt or clamps I haven't done? I have nothing but the most basic tools at my parents' house where I'm staying in Temple, TX.

This is a picture copied off Marlin's site just to illustrate what I mean. It's similar to the one I have.
<IMG SRC="http://dtay.freeservers.com/images/r150f_trans.jpg">

I'm flying back tomorrow at 9 am and have to leave town by
7:30 am to get to the airport in Austin. Greyhound opens at 7 am which is too close for comfort (today the clerk took 1 hour to do the paperwork on my transfer case for shipping).

Forward Air is too hard to arrange in short order. I don't have any shipping pallets or crates anyway.

TIA,

Dave

[MattS]

I don't know how to get them apart but 2 pounds? Are they empty? Drain em. That should take care of the 2 pounds.

[steveh]

Maybe you can un-bolt the bellhousing? Easy 2 lbs + right there

[Beanz2]

Done all that, drained the oil, took out the shifters and there was no bellhousing. I should have taken out the front bearing retainer and it would been sent by now. Darn bathroom scale says it was only 97 lbs

I decided to take out all the bolts I can get my hands on, the shifter plates, the front bearing retainer and saved 7 lbs. Let's see what American Airlines says tomorrow. If it's still over 100 lbs. I'm totally screwed. They won't accept anything over 100 lbs. even as air cargo. Then there is no going back to Greyhound.

Dave

[82FB]

i don't think there is a weight limit on carryons, and i am pretty sure that would fit in the carry on container. Just wrap it up in a tough duffel bag and carry it.

my brother carried a np205 adapter through before, and it was steel and weighed about 35 pounds. Got some strange looks, but no problems.

[YotaRunner]

That sucks, Hope they don't think it's a bomb, and delay you even more. Just tell them you've weighed it at two different places, and it comes in under 100. If not just make a huge deal out of it and mabie they'll just push you through...

[projectcrawler]

Here's my best shot.


1. Remove gear shift lever retainer(pink) and and the selector shaft rotation limiting pins(white) both sides. Take out bolts and loosen the transfer adaptor(blue).

2. Using a torx wrench remove the detent plug(yellow, I think that's it, if not look on the other side,below the limiting pins, it's angled downward ~45 degrees) from the transfer adaptor(blue), then using a magnetic tool, remove the spring and the ball.

3. Remove the transfer adaptor plug (rotate the housing so the rear is facing you and it's the upper bolt).

4. Remove the shift lever housing set bolt(inside, where shifter connects). Then, by threading a bolt onto the end of the shift lever shaft, pull and separate the shaft from housing. Remove the shaft and the housing. Remove the ten bolts from the transfer housing, then, using a plastic hammer, lightly tap on the transfer adaptor and slowly remove it.

5. Remove the eight front bearing retainer bolts(rotate so bellhousing end is facing you). Then remove bearing retainer. Using snap ring pliers, remove the two bearing snap rings.

6.Secure the transmission, and use a brass punch and hammer to strike in turn the exposed corners of the inch thick plate between the front and rear cases until the they are free from the case.

That should remove the front and rear case part(blue), might save you enough weight.

Good Luck



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[Beanz2]

projectcrawler,

Thanks for the great instructions! Too bad by now I've got it packed again minus all the bolts, bearing retainer, shift plates, limiting pins, etc. Anything I can turn with a wrench I turned and took off. Saved about 7 lbs.

After all that work, though, I found that FedEx Ground ships packages more than 100# (130# limit I think) . And they are even $20 cheaper than Greyhound!FedEx Rules!

Thanks for all the help guys!

Dave

[projectcrawler]

Glad to hear it worked out.



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