Transmission Shaft Lock Nut Removal Question

[AK Islander]

Pulled the manual tranny out of my '96 Exploder and planning to rebuild with new bearings, syncs etc. However, I couldn't figure out how to remove those doggone lock nuts. Finally ended up taking one off with a dremel and pipe wrench (without damaging the shaft, fortunately):



The other one is still on there:



Is there an easier way to remove these than cutting them loose? I've read that a punch can be used but haven't found any details or photos. Any tips for removing these dang things would be appreciated.

 

[Flash]

Ok, I'll say the obvious: you did undo the locking tab?

 

[AK Islander]

Yeah I "undid" it alright...the dremel pretty much removed the tab. Still couldn't budge the nut so I used a cold chisel to fracture what little material remained after the dremel cut. Then it was relatively easy to remove with a pipe wrench. It just seemed to me like I was doing it the hard way. I have no agenda or pride in my work other than getting it done properly and efficiently. If I've missed the correct and/or easy way to do this please share your technique.

 

[AK Islander]

So to narrow this down a little more, what I really would like to find out is how to undo the locking tab the correct way. Can this be removed without destroying the nut? As you may be able to tell from the first photo, I tried a variety of ways to persuade the nut from the output shaft. Tried lifting the tab with a center punch - the tab was unmoved but the punch didn't fare so well. Also tried drifting the edge of the tab outward with a pin punch with no success. After that a cold chisel (removed a little material) and finally tried drilling the tab out. This got most of the tab off but not to the point where I could move the nut with a wrench. The Dremel was the nuclear option but I was careful (or lucky?) and didn't cut or mar the shaft. However, I'd rather not risk doing it again on the countershaft.

There MUST be an easier way to remove these things. I live on an island in a small town so I can't just run down to the local transmission shop for advice. Any tips or instructions from the Exploder gurus would be appreciated.

 

[SoNic67]

I would heat the tab with a propane troch - just the tab, not the shaft.
It's easier to bend it back when red-hot.

 

[rb142]

The countershaft nut is easy. Just go get a 32mm (I think it was) socket for a few bucks and take it off like any other nut. That will let you re-torque the new one too.

You should be able to knock the tabs back up with a punch or similar. (If that destroyed your punch, you need a better punch.)

The pipe wrench is how many people take that main shaft nut off (and back on). Another option is to put a dull chisel or punch on the left end of one of the flats, and pound on it. That off-center impact creates a force to break the nut loose. Of course, a big enough wrench will work too if you happen to have one that big.