Hi all! New to both the forum and to jags, but found a sweet looking 2005 wagon a month ago and couldn't resist. Got it for a song because the transfer case is on its way out.



I'm no stranger to hard work, have done clutches on Audis and Volvos and the like; I'm stuck on this job, but not at the usual place one gets stuck.

I've got all the horrible brackets and heatshields out of the way, I've got the outer CV axle separated from the inner link shaft/stub axle, but I can't get the stub axle out of the transmission and transfer case.

Since I have the stub axle and CV axle separated, I was able to get a bolt threaded in to the end of the stub axle, got a steel plate behind the bolt, and then hooked a slide hammer on to the plate and started yanking away (an approximation of Jaguar special tool 100-012 slide hammer and 100-012-3)


No matter what I do, despite an hour or two of pounding away with a slide hammer hooked on to the axle, it only moves out about a quarter inch before the circlip on the other end which clips it in to the diff in the transmission stops it. Based on the two community writeups I've encountered plus the JTIS writeup, stub axle removal definitely isn't the usual hard part of this job.

Soooo...help? By some miracle, anyone else here happen to get stuck at this unusual step?

 

An update for the curious: also replacing control arms and shocks, so I pulled the driver's side suspension apart and pullet the CV axle on that side. The pin in the diff for the spider gear's is sort of in the way, but I can JUST see the end of the stub axle on the other side of the diff.



Despite the spider gear pin, I was able to get a giant screwdriver on to the end of the stub axle and give it several whacks with a mallet. Still no movement.

I'll give it some more whacks in the morning, but I'm already working on my next plan of attack for when that doesn't work.

 

This is pretty absurd. I mean, the thing is supposed to be easy enough to remove that Jaguar makes a special tool to keep from accidentally pulling the stub axle out too far. How can an itty bitty circlip be putting up such a struggle?

 

Have you consulted the downloadable srvice manual?

http://www.mediafire.com/file/xp3pxd...Manual.pdf.zip

 

I did indeed RTFM on transfer case removal. That's where my screenshot of tool 100-012 came from. I'm yanking away at the stub axle with a slide hammer just as per instructions, and she ain't moving.

 

From the manual, section on transfer case removal



From a bulletin on transmission removal, section on transfer case removal



Special tool 100-012 is a slide hammer, and 100-012-03 is an adapter which threads in to a hole in the linkshaft so the slide hammer has something to yank on. I'm yanking on the thing with a slide hammer, and she ain't moving.

 

This just keeps getting more and more peculiar.



Out of sheer bloodymindedness, I unbolted the transfer case from the transmission and tried prying them apart, and was able to get them to move. Hooray! The stub axle is no longer held in to the transfer case by the circlip: it and the transfer case both move about an inch or two along the transmission splines pictured.

The strange bit is that I still can't extract the stub axle from the transfer case. The stub axle is smooth along its length from the splines where it mates with the differential to where it exits the transfer case, yet it's behaving as though it's somehow fused between the concentric front/rear differential tube shaft and the stub shaft where it passes through.

The center differential, the site of that magical 60/40 power split (also a hollow shaft which the passenger axle and stub shaft pass through to clip in to the front differential inside the transmission.



A view from the transmission side of the transfer case, showing the hollow differential shaft where the stub axle passes through.



A stub axle sticking out of a transmission, with no transfer case so you can see the smooth portion where it passes through the concentric center differential shaft.



Somehow, between the smooth inner surface of the differential shaft and the smooth outer surface of the stub axle, it's binding or fused or something, and I can't pull the stub axle out of the transfer case. Even though I've overcome the stub axle circlip and it's no longer mated with the splines in the differential (it turns freely when I rotate it by hand), because it's still partway in the transmission, I can't yet drop the transfer case.

This is utterly perplexing. I'll return with my slide hammer in the morning when it warms up, but somehow it seems like the stub axle is fused with the center differential shaft. I'm absolutely baffled.

 

Hello again friends! Many months later, this story has a happy ending.

I eventually gave up and had the car towed to a transmission shop a local Jag specialist refers all their transmission work to. The shop I sent my car to ended up taking almost a dozen hours to remove this transfer case, though they only billed me for five hours since they reckoned originally it ought to take in the 3-5 hour range. Very nice guys, let me walk out to the car when they had it on the lift and talked me through all the steps they'd tried.

Finally, after unbolting the rear exhaust manifold, rear catalytic converter, and partially dropping the subframe at the rear, they were able to maneuver the transfer case and stub axle out of the car. I then had it towed back to my place to finish reassembly with a rebuilt transfer case and fresh stub axle/cv axle. As it's not my main car, it sat for a few months with the odd weekend hours here or there put in to slowly advance the project.

Reassembly went much much smoother, even with the extra things to tighten back down. On the off chance (well, it's an X-type, the eventual likelihood) that the transfer case fails again, I took an angle grinder and cut some of the more stubborn brackets and heat shields in to shapes that can be removed more easily. This bracket-***-heat-shield, for example, has now been separated in to a bracket AND a heat shield.



Finally got it together, topped up with fluids, and took it for a spin this afternoon. All is working well, at last. Time for an alignment.



This is the nonsense I was up against, and what drove both me and the saints at Advanced Transmission & Gear to the edge of sanity and back: the stub axle is seemingly permanently stuck inside the old transfer case. Even pounding it with a sledge won't free it. I will try to disassemble it in the coming days to get a better idea of the carnage inside.

 

 

I am also baffled, but this WAS a super unusual problem, perhaps no one had any advice to offer. I certainly can't find any other documented cases of the stub axle getting stuck in the transfer case.

 

Yep: sometimes you look at the post and think 'I have absolutely no idea'.
If beating it with a big stick fails then I am completely at a loss.
Good post though.

 

OK, time to perform an autopsy.



Driveshaft pinion gear came out no problem. All looks good inside so far.

From here, the going gets tougher. Most of the T40 torx bolts holding the transfer case shell together came out easily, except for two which stripped immediately.



Nothing an angle grinder can't handle.



Case came apart easily after that, and initially doesn't look too bad.





Tellingly, though, the mainshaft with the diff and roller bearings shows pretty significant wear and heat glazing on the transmission side (on the right). If I had to guess, I'd say this bearing failed and the whole shaft ended up a little bit cockeyed.




By standing the whole shaft vertically and dropping it sharply on concrete a few times, I was able to start separating components. The diff and its gear connecting to the (removed) gear on the idler/transfer shaft came away without much trouble.




The diff


The dreaded stub axle seals deep inside the diff. Two, one on each side.



This remaining piece is what was ultimately fused to the stub axle and prevented its removal. If I had to speculate, I'd say the initial bearing failure I noted earlier allowed the smooth stub axle to come in to physical contact with the inner cylindrical part of the diff you see here, rubbing until they seized.




Despite applied heat and pounding the whole thing with a sledgehammer (using part of the transfer case shell to hold it upright as I hammered away), it would not budge. I was able to apply huge amounts of force this way, certainly much more so than anything that could be done with the transfer case on the car, and it remained seized together.

 

No pics

 

 

Well that's a real pain in the posterior. Let me see what I can do with the links...

 

Pics now show with a "last update" showing 10 minutes after your last response post, thx

 

This looks like it was stressed pretty hard? You think so, particularly with the straight then spiral marks?

 

Definitely. This was the last piece that wouldn't come free of the stub axle. It's just a hollow part of the diff inside the transfer case, the stub axle is normally supposed to just pass right through the whole transfer case assembly without actually interfacing with anything inside. I reckon the failure of that outer bearing caused the mainshaft to just sit crooked enough for the stub axle to start making contact with this piece inside the diff. It wouldn't take much; when the stub axle was turned by hand, it was faintly but noticeably off its axis.