Doug H wrote this nice step by step:

D-18 teardown: http://thisoldjeep.fr.yuku.com/topic/220/D18-Transfer-Case-Disassembly#.USbO846L E20


Rick Stivers wrote this:

http://www.cj3apage.com/index/Tech_Tips/Model%2018%20Rebuild.htm

And of course, there are the factory service manuals.  Reprints are available from several sources.


Again, I have to stress that buying  your rebuild parts by price alone is a poor idea. If you can source NOS or New Old Replacemant Stock  (NORS) parts made in the USA for your jeep's gearboxes you will be a lot happier down the road. The countershaft is one part you do NOT want to cheap out on, with the imported soft metal relacements available that wear out in 3000 miles. Shy away from Omix Ada and Crown branded parts, and look for MADE in the USA on your replacements.  Peter Debella and Ebay are two good sources, and if you know of any others please add them below.

NOVAK ( the adapter people) also sells parts and a decent countershaft.

If you get desperate several suppliers can rebuild your gearboxes for you.  Ask your favorite parts supplier, and also check with Herm the Overdrive Guy.

Does anyone else have any hot tips for the novice transfer case mechanic?  Feel free to add your thoughts!