I am getting vibration connected to the transfer case or at least it feels bad through the 4wd selector handle. It is also leaking at the front of the case around both the front output and the input from the transmission. Transmission fluid checks good.
I am planning on parking it until I can drop it and tear it apart. From what I have read the 6 pinion planetary gear could cause the vibration and I am thinking I should replace that along with
possibly with the input shaft,
likely the chain, bearings, pump , seals etc...

This will be my first time ever in a transfer case.

Any parts manufacture recommendations? with shipping to south Texas?

Would there be a good chance of mass destruction in the case?

I have seen no impact guns , due to the likely hood of cracking the case.

The whole thing is caked with mud and now atf...

Any suggestions?

Is there anything I should be looking out for? ...

 

so far I needed a 1 1/8" for the front drive and a 1 1/2" for the rear drive. I have seen many people banging and prying these cases apart but it seems as though they were design to have a puller to do the work. I also needed a three prong 6 inch and a 10 inch puller for the drives(props?) and the tail housing. However the main case has tabs that I have not seen before to work with anything to pry it a part in a safer manner. Compared to others I not finding all the suspected snap rings. Any ideas to gain access to the chain?

 

I just went ahead and banged the case apart with a wide blow chisel and a hammer.

I had all kinds of trouble with the forward output shaft lock ring until I ground done on the straight style lock ring pliers until the fit in the ring grove. Its all apart ish I tried to leave things together for the most part until the morning when I will label everything and then go on a run to the local base to run everything through the parts washer and clean everything up press the bearings in and out etc. I am thinking Permatex gear case RTV sealant (81182) and since everything was done with what looked to be a non-smashed black RTV. All the beads of RTV seemed to be just 1/16" bead. I am thinking I will try and replicate the way it was and leave it sit for a long while hour plus before reassembly to avoid clogging up the filter to the pump. Has any body seen or done this any recommendations?
So far on a quick inspection it looked like the output seals were shot and everything else looks good. I will definitely go over everything during parts washing to ensure fine working order. Over all I am impressed by the case and the internals.

 

So I fingered it smooth and cleared off the rtv around the split of the case. The Rear I put it as close as i could to stock beads 1/16" and smoothed it down with my finger before putting it back together. I put 2 and a little more ATF+4. I originally thought I did something wrong cause it was really smooth shifting before I ran it looks like it works fine. I found a missing weight and the double cardan cv on the rear drive shaft was shot ball went through the race. Ordered a new rear drive shaft from Tom wood's. I drove it in 4 wd with out the shaft and it seems to be working fine. I will likely drain the unit at 100 miles and try and vacuum all the rtv out with a straw.

 

You should use Honda bond gasket sealer if that runs on trans fluid or some equivalent. It's used to seal gasketless 2 stroke cases. So gas doesn't even bother it. You can get it at any Honda shop. Don't even waste your money on that other stuff.
You may need an impact on some of those bolts.