1971 Body/Chassis FSM

1971-74 F Engine FSM

Page Index


Page 1 of 7

Rebuilding The 3 SP T-Case: Disassembly Page 1

What we are starting with

October 23th, 2007

Ok! All the parts are here so lets get started tearing the case down.

Fig. 1

Fig. 2

Fig. 3

Fig. 4

Fig. 5

Fig. 6

  1. Start by removing the cotter pin holding the E-brake drum nut in place (See Fig. 1) then use a impact gun with a 27mm hex socket to take the nut off.
  2. Slide the drum off the shaft. Inspect the seal area of the drum, if it is grooved you will need to get a speedi sleeve for it or replace it.
  3. Remove the e-brake shoe springs, adjusters and levers. The shoes are held on with retainers! See Fig. 2.
  4. Remove the 3 8mm x 1.25 x xxmm bolts plus 1 8mm x 1.25 x xxmm bolt holding the backing plate on with a 12mm wrench. See Fig. 3.
  5. Remove the 5 8mm x 1.25 x xxmm bolts holding the speedo housing to the t-case with a 12mm wrench. See Fig. 4.
  6. Tap the housing loose with a rubber mallet and slide it off the shaft. There will be a set of shims behind the housing. Do NOT loose these shims! You will re-use them later. See Fig. 5.
  7. Remove the bolt holding the speedo gear. Slide the gear and shaft out. Inspect the gear for wear. Now is a good time to order a gear to change the speedo ratio if needed. See Fig. 5.
  8. Slide the speedo drive gear and the spacer off the shaft. Note the beveled edge of the spacer will go toward the outside when you reassemble! See Fig. 6.

Fig. 6

Removing Companion Flange

Fig. 7

Removing Shift Shaft Housing

Fig. 8

Removing Extension Housing

Fig. 9

Housing Removed


  1. Remove the front companion flange cotter pin and use an impact gun with a 27mm hex or 1 1/8" hex socket to remove the nut. Slide the flange off the shaft. Don't loose the washer and nut! See Fig. 6.
  2. Make sure the 2WD/4WD shift shaft is pulled all the way OUT. Use a 12mm wrench to remove the 4, 8mm x 1.25 x 55mm, bolts holding the Shift Shaft housing to the Extension housing. See Fig. 7. Use a rubber mallet and tap the housing to loosen it. Separate it from the extension housing being careful not to break the shift fork. Set it aside for now.
  3. Using a 12mm wrench remove the 5 bolts holding the extension housing to the T-case. Tap it with a rubber mallet to loosen it. Slide the extension housing off. See Fig. 8-9.
  4. Use a long screwdriver or punch and pry out the oil seal in the end of the extension housing. See Fig. 10.


Fig. 10

Removing Oil Seal

Fig. 11

Removing Bearing Retainer

Fig. 12

Bearing/Shaft Removed

Fig. 13

Bearing Removed

Fig. 14

Housing Parts

  1. Refer to Fig. 11 to locate and remove the spit ring that retains the bearing. This is a bit difficult but once you get one end started it comes right out.
  2. Next we need to remove the bearing with the shaft from the front extension housing. Invert the housing and support the end of the housing with wood or metal blocks and use a plastic mallet or wood block or a press and press the bearing out of the housing. See Fig. 12.
  3. Next remove the bearing from the shaft. If you have a hydraulic press use a bearing cup to support the bearing and press it off. If you don't then use two blocks of wood and a plastic mallet or block of wood. See Fig. 13.
  4. Fig. 14 shows all the Extension Housing parts.

Fig. 15

Shift Cover Removed

Fig. 16

Removing Shift Fork Spring Retainer

Fig. 17

Driving out Shift Fork Shaft

  1. Using a 12 mm wrench remove the 8 8mm x 1.25 x 25mm bolts holding the top shift cover to the T-case. See Fig. 15.
  2. Remove the cotter pin and use a flat screwdriver to remove the shift fork spring retainer. Under the retainer is a spring and a metal ball. A magnet is helpful for removing the ball. See Fig. 16.
  3. Use a punch to drive out the shift shaft. See Fig. 17. Remove the shift fork.

Up Next: Disassembly Page 2




1971 Body/Chassis FSM

1971-74 F Engine FSM

Page Index

Hosted by Global Software, Inc.

©1998 - 2023 Mark C. Baker Web Designer

Please: No part of this web site may be used without express permission... email mbaker@globalsoftware-inc.com for permission.