I'm trying to put the Calmini 4 2 1 gears from the tcase I got from 37kicker into my old stock tcase which is in much better shape. I can't get the clutch reduction gear off the main shaft of my original tcase, won't budge. Same clutch gear came off the case I got from 37k without a problem. I've tried heating with map gas torch, 3 jaw puller, it just won't budge. Any ideas would be GREATLY appreciated. Yes, clip has been removed.
 

Freeze it overnight and try again?

Not exactly sure what your talking about, but that's on my end. Did you happen to look at the gear installation article we have on the 'site? It may help... or at least get us on the same page as to what part you're trying to pull. I think your talking about step #13.

From the Gear Guide section:

http://www.zukiworld.com/month_010103/feature_calminirockcrawler_sidekick.htm

 Eric

Yep, step 13 allright. I mispoke, it's actually the clutch reduction hub. I was using the sites gear install article, as well as the FSM as a guide. First ( old ) case came apart easy. Examination showed the face of the clutch hub scored pretty good. I soaked the hub in the replacement case with PB, gonna let it sit. The  tcase it's in has been sitting for 4+ years but it was sealed and there was no noticeable corrosion on anything inside.

The lock ring seems to make a little ridge around the splines, and makes the
hub hard to get off, otherwise a gear puller may be in order, I've had them
stick and hang, but never that bad.

Good Luck
Wild

Thanks Wild, the only gear puller that will fit between the two gears is pretty small. I've been letting it soak overnight in PB Blaster and I'll give it another try after work today. If I can't get it off I guess I'll need to look for another Tcase.

What a stubburn BITCH!!! Came home from work and went right at it, Nothing, nada, ziltch, didn't budge. At least I figured out where all the noise and grinding sounds were coming from. First, the drive chain is totally streached and sloppy, twice as much play as my replacement case ( my original case) and both the face of the clutch hub and the gear face it rides against were scored from a lack of oil getting to them. I talked to Mike who builds all the transfer cases and transmissions at Trail Tough and he gave me a great tip: galling between those two parts is a known issue with a certain mfgs gear sets, so he always grinds some oil grooves into the clutch hub face to get more oil to it. If I can ever get the damn thing off I'll do just that. IF  I get it off.

   I give up. Wasted another hour and 45 minutes messing with that thing. I've spent more time trying to get that damn clutch hub off then I did pulling all the skid plates, and removing the damn tcase. Looks like I'm getting another decent used one to try, hope the hub comes off this one. Man, the shit we go through for our Zuks.

You could knock the shaft out all the way so there is room to
work and get it off, just a thought

You could knock the shaft out all the way so there is room to
work and get it off, just a thought

I'd have to disassemble the back half of the tcase, and even so it's so stuck I'd probably crack the case trying to knock it out. Screw it, I found another tcase. I just hope this one comes off. If the rest of the old tcase parts weren't so worn out I'd just resurface both gear faces and call it, but the whole thing is just WORN.

Ya, once you are into the case, it's not much more to take it all apart,
but anyhow you got a replacement.

Don't forget to remove the middle detent ball bearing so you can do a
twin stick while you are in there, or have you got a twin stick for it?

If you have not, do it, it is so cool having 2WD low and turning with
a front locker is a dream, I did most of the trails in Moab in 2 wheel
and only hit 4WD when I started to slip or got stuck, and it really takes
a lot of stress off the front driveline and the t-case chain too, I recall
how loose you said one of the cases chain was, so .....

Wish I were closer, I'd come over and help you with the little $#%&*

Good Luck
Wild

I agree with Wild.... def do the twin stick while you have it apart, you wont be disappointed.

All ready got the twin stick setup, and you are right, makes it so much easier and nicer to drive. If I didn't put the Calmini low range gears back in I could be up in a matter of hours, but their just too good to leave out. Looks like I'm going to be up on the jackstands for awhile waiting on the newer case to arrive. Just as well, it'll give me time to get under there and wash off the accumulated mud and gunk from a summer of Jersey rain, and I've been puttin in 12/14 hrs a day lately anyway so evenings are pretty much wasted. When it rains it pours. Oh, and thanks for the help offer Wild, I wish I was closer to any other Zukers. Kinda funny, none of the guys I've been out with have offered. I guess I will start charging for rescues now! 

Took a chance and dropped it off at a local trans shop to see if they could do something with it. I won't know until mon or tues but hell, can't hurt.

Update: still haven't heard from the trans shop. It's probably still sitting in the milk crate I dropped it off in. I hate waiting for other people to do work for me that I should be able to do myself. I'm abobut ready to just pick the damn thing up and CUT the old clutch hub off.

Yea, it can get aggravating.  Let us know how it works out and what they had to do.