I made some pretty good progress tonite:
Tight spaces when I am working at night with the garage door closed.
Borrowed a deep 36mm socket from a friend.
Got off the nut from the flange, then used a 3 jaw puller to get the flange off
Case is still together very tight, so I got out my favorite Harbor Freight tool, the gear puller set:
The rod threads fit perfectly into the threads in the case
Finally, after being ever so gentle with it, I heard a slight pop sound....
Some kind of device to prevent the chain from hitting the case/prevent falling off?
Transfer case details
Planetary gears transmission input
This is how loose the chain was
Needle bearings in the cover over the back of the front output shaft
Needle bearings in the cover for the trans/rear shaft
Chain was making contact with the pad
Took the planetary gears off
The spacer and needle bearings in the top left corner of this next pic came out while I slid the bigger gear off the shaft.
Had to remove the pad to get the chain off the smaller gear
Chain comparison:
New (lighter colored)chain is so tight it doesn't bend as much as the old (darker)one
Transmission input shaft taken out to put on new chain
New chain is so tight, the big gear is hard to go back in (without removing the smaller one)
Since I want to remove as little as possible, I 'help' it a little
In and nice and tight
Planetary back on.
Need some sealant like what was on there before, some grey stuff....this maybe?
DAMMMMmmmmm, the sealant is dried up, so close yet so far....anyway, I feel good about getting into the case and getting the chain on.
I was so anxious to get the case back together I started getting Krazy!!@#$
OK, just kidding....I will call it a night for now.
P.S.
I found out from
RealOEM.com Online BMW Parts Catalog that I can buy the exhaust stud as a dealer part ($2.50 from PelicanParts.com), so I will use a socket and a C clamp to try and get the broken one out.
(They also have all the shaft seals for the transfer case, just in case...)