samurai speedo gear removal (transfercase)

[westcoaster]

So, your speedo has stopped working and you have determined that the speedo gear is faulty. (tab is broken)

You wander off to your trusty factory service manual and see the guy removing the speedo gear with a pair of pliars. Now, that SOB is working on a snazzy NEW transfer case not one that has been sitting under a samurai for the last twenty years.

Here is how I made my puller.


I started off with a carrage bolt and ground down the head to fit down the speedo hole.

I then drilled a hole through the end of the bolt.

I then scrounged through my parts drawer to find a hardened steel pin that would fit through the bolt hole (that secures the speedo cable to the transfer case). I then ground the length down so it would be a little longer than the diamater of the speedo gear hole.





place the bolt head in the gear hole and poke the pin in using a small screw driver.



I then hung a trailer spring on the bolt  and threaded on a nut and washer.


The spring was simply there to give me something to hit with the hammer....


A couple whallops with the hammer later.....

[Bingo Jed]

genious! 

I'm sure I'll be needing to do this soon.

Is is possible to do this with the case still installed or does it have to be removed?

[westcoaster]

genious! 

I'm sure I'll be needing to do this soon.

Is is possible to do this with the case still installed or does it have to be removed?

According to the factory service manual, the speedo gear can be removed with the transfer case still in the vehicle.

The only "problem" I can see with my puller is that it may not work on functioning speedo gears with out cutting a notch in the head to clear the tab that drives the speedo cable....

[Surly]

The only "problem" I can see with my puller is that it may not work on functioning speedo gears with out cutting a notch in the head to clear the tab that drives the speedo cable....

...and your pin would fall out.

[westcoaster]

...and your pin would fall out.

Just got to keep the pressure on it....

on another note, I was about to attempt the puller on the tcase that was in the samurai. I pulled the retainer bolt and started tugging on the speedo cable. I'll be darned if the gear didn't simply pop right out with the speedo cable still attached.

[ZUKIMON]

That's a pretty slick idea there.