Spicer 18 Transfer Case

Disassembly:
Nothing yet...
Assembly:
Main Case
Rear Cap
Front Cap
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Spicer Model 18 Transfer Case D18 in Itty Bitty Pieces   These pages could be titled How I Assembled My Transfer Case. I used three sources of information during this process: (1) The instruction sheet that was enclosed in the intermediate shaft kit from Novak; (2) Willys Service Manual; and, most used, (3) Rick Stiver's Transfer Case Rebuild Guide. Rick's guide is on the web and a link to this guide is provided at the top of the page. If you're planning on rebuilding your own case that should be your first stop. I did, however, do things somewhat differently than detailed in each of these sources. As I have not yet been able to run the assembled transfer case I don't know how well it all worked out so follow my process at your own risk! ;-)

Below are a few suggestions to consider before beginning the assembly process.

 
 
Measuring Intermediate Shaft 'Wobble'   Completely disassemble the transfer case and inspect all parts before ordering ANYTHING! I started out thinking that all I would need would be the intermediate shaft, bearings, and gaskets. So that's what I ordered. After taking things apart I didn't like the intermediate gear - it seems that gear (642189) is getting hard to find but I found one and ordered it. Here's where things started snowballing:
  • My original case turned out to be toast. The front hole for the intermediate shaft was enlarged a bit - allowing 0.036" to 0.038" wobble on the shaft (as pictured to the left.)
  • My replacement case (NOS tagged as a 1-1/8" case) turned out to be the later 1-1/4" case. A fellow WillysTech member offered a good 1-1/8" case (thanks Chuck!) Decided to use the original gears in the 1-1/4" case and build the 1-1/8" later for a spare.
  • Front output shaft was worn as was its bushing.
  • Shift forks were worn and needed replacing.
  • Shift rods had rough spots where the seals made contact and the notches for the shift levers were badly worn.
One thing led to another and wound up with an almost entirely new transfer case. It would have been cheaper to have bought a rebuilt case! So inspect everything and make a list of what needs replacing. Find out how much it would cost to replace these parts and compare against the cost of a rebuilt unit (about $400 currently) and decide what's best for you. I probably spent about $600 rebuilding this case - it was fun but I'm not sure if it was worth it. ;-) 		 
 

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Copyright © 2000 David Hoelzeman
Last Updated: May 27, 2001