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Removing transfer case V5 STi RA DCCD box


dimin

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So have a V5 RA that has the common pop out of 5th issue. In process of trying to remove the transfer case, with the box still in the car. Following a tutorial off an overseas forum, Im now stuck with the shift rod stuck in the shift fork notches. No matter what I do it wont turn or move, and cant figure out how it disengages ? Anyone who has done this fix, is it correct that there is a collar under the DCCD top cover that needs removing? And if so I assume I would have to remove the box entirely to access this as there is limited room between box and chassis with it in the car. Any help appreciated, cheers !

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Yes there is a "collar" under the rectangular cover a 10 mm fitted bolt (don't drop it inside the box!) locates the selection lever to the rod. Must be removed to allow housing to come away.

Damn site easier to remove the whole gearbox to do this though. Good luck doing it underneath the vehicle.

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Thanks for confirming that, thought the box would have to come out, such a mongrel of a job without a hoist, etc. Pulled it tonight and got the transfer case off easy once that retaining bolt removed. Sure enough the main shaft nut had backed off. New nut, gaskets and put it all back together and hopefully good as new.

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