I have a redundant countershaft in my car's transfer case which I need to remove. I'd leave it in there but the bearings are starting to make noises.
Basically I need to cut this shaft in half in situ in order to make room to get it out. It won't come out in one piece. Removing the transfer case isn't an option.
What's a good way of cutting through it? Preferably making as few sparks as possible.
I don't have enough room to get an angle grinder on it, at least not all the way through the cut. I'll try a hacksaw but I feel I'd be there a long time.
I hope there's some magical tool designed just for this application that someone knows about
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I use a torch quite a bit, and when cutting, small bits of molten metal fly everywhere. It would be hard to clean all of these out of his transfer case.
The only hope for a torch would be if the shaft was small enough that you could heat a section of it it red hot and then just bend it out without ever hitting the torch cutting lever.
I vote for the sawzall too- unless there was a way to pull a snap ring and push a gear out of the way so it is disengaged form the driving gear so the shaft no longer spins.
I was thinking that you would wedge some aluminum flashing (or something like that) behind the shaft to limit the exposure to debris, but maybe I'm assuming there's a lot more room there than there really is.
The only picture I can find of a countershaft in a transfer case is a for a big Mercedes SUV... and It appears that the space is different than I was thinking. Is the problem that the shaft is too short (i.e. there is no room to get a tool in between the gears on the end)?
Maybe you could rent an electro-hydrolic cutter? I don't know where to rent one, but they come in sizes from .5 in bolt cutters up to Jaws of Life type stuff...