Engine/Transmission (1998.5 - 2002) NV241HD Transfer Case Output Shaft Bearing Retaining Clip

[John]

Ok...



how in the heck do you remove this (external type) snap-ring (i. e. , retaining clip)?



The long version... (remember, this is a NV241HD I'm talking about)



I'm trying to replace both my output shaft seal (again ) and the output shaft bushing (which is located just ahead of the aforementioned seal). So far, so good ( ) Ok, here comes the fun part. After removing the four extension housing bolts (tailshaft housing... whatever), and a light smack with a dead-blow hammer, I figured that bad boy would come right off... but nooo! Ok, time to check the FSM. A quick check revealed that there is an access port somewhere on the extension housing in which you can release the snap-ring thereby releasing the output shaft bearing. Ok, I look all over the extension housing and low and behold, I find an elongated "rubber" cap on top. I quickly remove that and try to figure out if I have whatever tool it will require to release the snap-ring. BTW, the snap-ring is the same style ("pointed", back cut ends) as used on the turbo silencer ring, snap-ring.



So my questions are:



1) What tool(s) is/are used to remove/release the snap-ring? Keep in mind that there is not an over abundance of overhead working room... I know this because none of the snap-ring pliers I have will work in this semi-confined area.



2) Is the snap-ring completey released, or just spread wide enough to somehow slide the extension housing off?



2A) If that's the case, how in the heck would you accurately and completely reinstall said snap-ring?



Thanks in advance for any tips you may want to share.

 

[Todd G]

I don't think the output housing is any different on the two transfer cases. On my LD case, the tail housing came right off. Nothing to hold it on but 4 bolts and sealer. My manual says the same thing. The snap-ring holds the output shaft in the main case or at least keeps it from moving back and forth.

 

[John]

Todd, I read the section in my FSM on the NV241LD transfer case as it pertains to extension housing removal. You see, the extension housing on the LD version is a two-piece affair. You unbolt the rear section of the housing which in turn directly exposes the snap-ring for ease of removal. After that, the other half (or piece) of the extension housing can be removed. It seems quite a bit more logical to me.



On the HD version, you have to reach through the little slot in the extension housing with the correct tool (that will also fit within space constraints) and release the snap-ring.







... and to think I gave all my buddies a hard time for buying the "low-rent" LD version...

 

[Dane]

John,

Does the snap ring have the little holes on each end of the ring? If so snap ring pliers should do the trick.

 

[John]

No Dane, sadly enough the snap ring does not have the holes. Instead, it has the angled, closed angle ends at the outer periphery of the ring... just like the turbo silencer ring on a Holset HX35.

 

[John]

Originally posted by Todd G

On my LD case, the tail housing came right off. Nothing to hold it on but 4 bolts and sealer. My manual says the same thing. The snap-ring holds the output shaft in the main case or at least keeps it from moving back and forth.

After re-reading your post several times I thought I would further elaborate on my removal procedure. Before I even came in to start this thread last night, I had already tried lightly prying the extension housing off with two screwdrivers. Once I had lightly smacked the extension housing with a mallet, it was free enough to separate from the main transfer case housing... but only by a 1/4" - 3/8" or so. That's when I got the idea that what I had previously read in the FSM awhile back may have some merit afterall.



You see, I have had two other NP208 transfer cases before, replaced multiple seals in same, along with an output shaft bushing in one. There, after the removal of the extension housing to case, bolts, the housing more or less slipped right off (as I remember... which was at least 13-15 years ago. Think this is a case* of CRS? )



*pun intended (sort of :-laf )

 

[Todd G]

I stand corrected. For all the transfer case snap rings, I used snap ring pliers I bought at Sears. They have the flat paddle tips that hold the snap rings pretty good. $15 or so. A friend at a heavy transmission shop used Snap-On pliers that were a foot long! I'm sure they cost quite a bit more but made the job look very easy.

 

[John]

Originally posted by Todd G

I used snap ring pliers I bought at Sears. They have the flat paddle tips that hold the snap rings pretty good. $15 or so. A friend at a heavy transmission shop used Snap-On pliers that were a foot long! I'm sure they cost quite a bit more but made the job look very easy.

Ya but...



I have "overhead" space limitations in which to insert the tool into the access hole and maneuver/manipulate the snap-ring. I'm sorta still lookin' for answers to my original questions in my thread stating post [1), 2), and 2A)]



BTW, I have a pair of those "paddle" type pliers to remove these sort of snap-rings however, it looks as though I'll need a pair of 90 degree tips at least several inches long.



Thanks for your help Todd.





Hmmm

 

[tree truckr]

John,



With the extesion housing loose is it possible to rotate it around to be able to at least see what your doin in that little slot and maybe reach in there with flat blade snap ring pliers ?

Just a thought, never seen one like it before.

 

[tree truckr]

John,



With the extension housing loose is it possible to rotate it around to be able to at least see what your doin in that little slot and maybe reach in there with flat blade snap ring pliers ?

Just a thought, never seen one like it before.

 

[John]

Hmmm...

I'm not sure if the extension housing can be moved away from the transfer case body far enough to clear the alignment dowel in order to rotate it for easier snap-ring access. I will surely look into that.



I purchased a pair of Craftsman Lock-Ring Pliers today so I could butcher or otherwise modify them to suit this particular task... as opposed to attacking my Snap-On counterparts.



Thanks for the ideas...



keep 'em coming!

 

[John]

Nope! Just as I suspected, the main case to extension housing dowel alignment pin is impeding my effort to rotate the extension housing (i. e. , the extension housing cannot be moved away from the main case enough to clear the dowel pin).