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Old 10-24-2010, 09:53 PM   #26
MARKSTIV8
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So llamsn, did you already put everything back together?
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Old 10-25-2010, 11:20 AM   #27
klinebau
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I am gearing up to replace these bearings myself. I am piecing together the parts and tools needed to complete the job. I will probably purchase a press since I don't know anyone that has one. Here are things that I think are needed. If you think anything else is needed, let me know.

Parts:
Replacement bearings (4) - part numbers listed above
Turbo to downpipe gasket
Permatex ultra grey to reseal the extension case
Transmission oil

Tools:
Hydraulic press
Bearing separator
Snap ring pliers
drift to remove shifter trunion roll pin (already have)
various wrenches, sockets, allen keys, etc. (already have)
torque wrench (already have)
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Old 10-25-2010, 10:41 PM   #28
llamsn
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MARKSTIV8,

I put everything back together and everything seems to be working alright. I've put about 250 miles on my car so far. The whirring is gone and I don't hear any new noises!

klinebau,

I have a couple of things off the top of my head.

-I would suggest having 2x 12mm open end wrenches for the nuts and bolts on the rear diff side of the drive shaft.

-I see that you're in MI. I would suggest having some of your favorite penetrating oil (my car is from MN)!

-It was suggested to me that I use the red high temp gasket maker (at dealership). It's the same stuff that was used on my rebuilt transmission. The companies website also states that the red is resistant to auto and shop fluids.

-Be prepared to let you car sit for 24 hours to let the gasket maker cure

-Mark where the drive shaft meets with the the rear diff. I'm not really sure if this matters with this car (I've been unable to find this), but not doing so has effected other cars I've owned in the past.

These are basically the steps I took to get the bearings.

Jackstands, jackstands, jackstands!
Remove skid plate
Drain tranny
Disconnect O2
Remove 2nd cat (2nd part of dp)
Remove drive shaft cover
Remove drive shaft
Disconnect shifter linkage
Tap out pins and remove knuckle
Unbolt all tail shaft bolts

I wasn't ready for the amount of fluid that drained from the tail shaft once I broke the silicone seal. I would suggest having a drain pan ready!

Break silicone seal and let drain!

The transfer driven gear will probably come out when you're removing the housing (it did with mine). I suppose the center diff could as well, but it stayed in place for me. Be ready to catch them! The Forester link that I provided earlier in the post is very helpful with this!

Slowly remove tail housing.

The transfer drive gear should stay put in the housing you just removed (the flanged bearing has 4 Allen bolts that hold it into the case).

Remove center diff. It slides out easily. It's just a bit weighty.

There might be more, but I'm getting tired. I hope this helps!
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Old 10-26-2010, 12:08 AM   #29
klinebau
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Thanks for all the help. I purchased a shop press today and I ordered all of the new bearings. Thanks for the tip on the gasket material. The part numbers earlier in the thread were also very helpful. I intend to take pictures and document everything, but it will probably be a week or two before I get around to fixing the car. I will make a new thread when I do and include a link into this one.
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Old 10-27-2010, 06:18 AM   #30
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So the entire tail housing is being removed from the tranny? (that foot long piece) or just the cover at the end?
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Old 10-27-2010, 09:08 AM   #31
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Quote:
Originally Posted by ragejed View Post
So the entire tail housing is being removed from the tranny? (that foot long piece) or just the cover at the end?
You just remove the tail end cover and you can pull the guts out.
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Old 10-27-2010, 02:37 PM   #32
09rexwagon
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FYI guys, this HF 12 ton press is on sale for $90:

http://www.harborfreight.com/12-ton-...campaign=4310b

I have a coupon (I get the email coupons) for the $89.99. PM if you want me to forward it.
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Old 10-27-2010, 07:11 PM   #33
MARKSTIV8
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So everything works, awesome!

Now let's see those pictures!:]
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Old 10-27-2010, 07:29 PM   #34
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Quote:
Originally Posted by MARKSTIV8 View Post
So everything works, awesome!

Now let's see those pictures!:]
+1 for pics, ill host them!
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Old 10-28-2010, 04:27 PM   #35
klinebau
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Still waiting for parts, looks like I won't be able to start until next week.

What is the size of the allen bolts for the transfer drive bearing that attaches to the extension case?
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Old 10-29-2010, 12:48 PM   #36
llamsn
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I've been busy, but I'll try to post pics by the weekend...
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Old 10-29-2010, 08:54 PM   #37
ohemgeeitsNiko
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sooo, i was getting ready to do this and i drained my tranny fluid and these came out with it.

does anybody recognize these pieces? maybe they're shims? i'm not sure but they look to be part of a circle.

i used my index finger as a base of comparison for size. :P

the car began surging and popping when in gear. any gear. it started off by just the typical whiring noise, then it slowly got worse.

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Old 11-03-2010, 07:23 PM   #38
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pics pics pics! do i need to paypal you some $$$ lol
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Old 11-04-2010, 11:47 AM   #39
klinebau
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My parts came in the mail yesterday (looks just like the picture earlier in the thread). I plan to start the replacement this weekend and will snap some pictures along the way.

ohemgeeitsNiko's mystery pieces may be part of the snap ring on the center differential. Apparently that is the cause of drivetrain noise that some owners have experienced. I only hope that my center differential is ok when I open up the transfer case.
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Old 11-04-2010, 06:42 PM   #40
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Ya, I have all the bearings, seals (driveshaft and shifter) and new center diff all ready to go. however I dont have a shop to press the bearings in this weekend
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Old 11-05-2010, 11:11 AM   #41
ohemgeeitsNiko
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soo, i pulled the trans out and started breaking it down. here's what i found.





and i can't get the stupid diff out.


and now i'm handicapped. i was breaking the four allen bolts that retain the bearing in the end cap, i broke the fourth one and my hand slid against the case, a trip to the hospital and 5 stitches later, i can't work on ****.
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Old 11-05-2010, 01:22 PM   #42
MARKSTIV8
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Damn! Happens to most noobs who start working on cars, I have my scar too.


llamsn: what did you do about the clearances?If anything
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Old 11-05-2010, 01:29 PM   #43
Storm
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Yikes! Good luck with the hand!!!


The diff should come out if you flip the housing over.....maybe a bit of tapping to the sides.


Jay
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Old 11-05-2010, 05:04 PM   #44
llamsn
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I was out of town at the beginning of the week, but I'll try to post pics when I get back tonight. It's a matter of hosting them with brief descriptions.

ohemgeeitsNiko,

Sorry to hear about your accident! I'm guessing that most of the shrapnel is bearing race. However, I would be concerned about your center diff. The diff just slid out for me. It's probably heavy lifting it straight out. But what is catching my eye in your pic is the ring coming undone. Notice the metal ring on the outer edge of the center diff. It actually holds the pieces of the the diff together. It's kind of like a large snap ring, but I don't think it's serviceable. Here's a photo of what mine looks like:

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Old 11-05-2010, 05:13 PM   #45
llamsn
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MARKSTIV8,
Which clearances?
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Old 11-05-2010, 06:38 PM   #46
MARKSTIV8
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All the clerancess, you posted the FSM page with them on the first page. I guess that you didn't bother with checking them, but everything works so that's important.

On a side note I just opened my tranny and bad news is that all of the bearings and center diff look great, something else is the cause of whine and grinding.
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Old 11-05-2010, 11:34 PM   #47
ohemgeeitsNiko
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Quote:
Originally Posted by MARKSTIV8 View Post
Damn! Happens to most noobs who start working on cars, I have my scar too.


llamsn: what did you do about the clearances?If anything
i'm no noob! lol. i built my motor myself, nothing went wrong. lolol.

but still, it was unexpected and an irresponsible mistake, i had a pair of gloves not even an arms length away that would've saved me from this nasty flap of skin.

so yeah, kinda sorta found a big hole through the diff. chamber. picking up a parts transmission tomorrow morning.
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Old 11-07-2010, 12:09 AM   #48
llamsn
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MARKSTIV8,

I only replaced the bearings. I was informed that it wasn't an issue unless you replace the tail shaft housing, the drive gear, and/or driven gear.
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Old 11-07-2010, 12:57 AM   #49
llamsn
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Quote:
Originally Posted by MARKSTIV8 View Post
On a side note I just opened my tranny and bad news is that all of the bearings and center diff look great, something else is the cause of whine and grinding.
Did you look carefully at the rollers and both cones? Mine looked OK until I noticed the pitting. Have you also checked the bearing mounted in the tail shaft? Is there a lot of play with the roller bearings? I had a miniscule amount of play with the new roller bearings compared to the old ones. I didn't realize the amount of play with the old bearings until I had the new ones to compare them to.
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Old 11-07-2010, 01:32 AM   #50
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Here is a link to a few pics hosted. I'm having problems loading all of them.

http://goo.gl/FSi63
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