5th gear in w59 removal

I'm trying to get 5th gear off of the shaft and I can't for the life of me budge the damn thing! Im using the FSM and it states to pull both the gear and bearing off with a SST... I'm not made of money and I've had good success in the past with HF pullers but I'm just getting whooped

I've tried two different styles of pullers and was able to get the bearing off but this gear will not come! Any help would be appreciated


Also can you give me your opinions on if this damage to the spline is something I need to worry about?

 

@gearcruncher

 

Have you tried a three jaw with an impact? (use a shaft saver) run it tight and give it a whack w/ hammer

 

I tried a 3 jaw ... but I dont have a shaft saver... after the initial marks you see I created, I stacked 2 washers on the point of puller to try and save it


I was afraid of breaking the HF puller if I used an impact ... i did try whacking it with a hammer after tightening it with a wrench though

 

Didn't somone else just run across this?

I think they had to shock it harder.

Maybe a search? Not being smart azzed, I know it's a rare question in general forums.

We all like to be familiar even if just so we don't get ripped off.

edit: I think the guy had to use a better puller too.

 

Thank you, I'll search harder... I did find a recent thread where the guy blew up his intermediate plate trying to pull the 5th gear but it wasn't clear on what he did to actually yank it. I'll go reread it again just in case

 

https://www.tacomaworld.com/threads...arings-themselves.593972/page-2#post-19910964

maybe some help? I was thinking of this one.

 

Perfect! I hadn't come across that one, I'll try the heat and brass hammer trick.... have you torn into these before? Can you inspect the last 2 pictures I have and see if I should replace that shaft while I have everything apart?

Those are the splines that slip into the xfer case

 

I see your concern but have no advise. I'm no trans. man, I only go in them when in a bind such as yourself (maybe)?

Money's a concern, I get it.

@gearcruncher may be able to throw a bone.

edit: If forced to use though, I'd clean as much sharpness off those bites I could.

 

Thank you sir, I agree with that action... I honestly had ZERO reason to tear into it other than a desire to have this truck as close to brand new as I possibly can I figured I just put a poop ton of money into complete rebuild of the motor, it woulda been a shame to slap a 229k trans to the back of it, especially since I did some mild upgrades and with my luck I'd blow a seal with all those "extra ponys"

 

I have a whole other different W59 out of a donor truck I could tear apart just for that shaft, but with the effort I've put into just getting it torn down to this point I really didn't wanna do it all again

 

I played a machinist on TV for alittle while and the more I zoom in on the marks, the more it looks like the recessed portion is actually mis-machining from factory and the hard edge is something that broke after the fact? It definitely ran like this for awhile because there's no burr like metal that just broke

 

find an older copper penny and put that under the point of the puller on the end of the shaft.

 

Thank you, that's a good idea .... probably much better than the hardened washers I was using