Front output gear

[TheWipprSnappr]

Disassembling this 5 speed transfer case to rebuild it with the good parts from my automatic one.
Is it just me or is the front output gear not supposed to look like this:



The one in my automatic looked like this:



With the one in the first picture, how the hell am I supposed to pull the bearing behind it. Better question, how did the install it like that with the bearing and seal?


Inside the case:

[D.Martijn]

Those splines on the output shaft are definitely shot.

This is the tool to remove a bearing that's installed like that. Search blind hole bearing removal tool/puller.
It hooks/tightens itself on the inner race which allows it to get slide hammered out of the casing.

[TheWipprSnappr]

yes, thats why im replacing them.

I cant get to the bearing tho if i cant pull the gear out, since the end is flared. Why are some flared and some are straight?

[TheWipprSnappr]

Got it out, Ended up hitting hard enough a couple times to force the gear out with the bearing

[D.Martijn]

Oh, now I see. There should be a big snap ring on the outside of the shaft but I can't seem to locate it on your picture. Is the flared metal thick? Since the shaft is no longer usable I would use a punch and hammer it towards the center of the shaft.

Snap ring is pictured here, part 26.

https://www.realoem.com/bmw/enUS/showparts?id=AG05-EUR-05-1992-E30-BMW-325ix&diagId=27_0003

[The Dark Side of Will]

Disassembling this 5 speed transfer case to rebuild it with the good parts from my automatic one.
Is it just me or is the front output gear not supposed to look like this:

WTF? That's rather ugly. I have no idea how that would happen.

[nando]

damn, that is hammered - must have been driven for thousands of miles that way. :(

if you tap on the case to open it that bearing will just come out with the shaft. Then you can pull it off the shaft after cutting the 'flared' part off - if it's still any good, that is.