Well, today I drained the transmission fluid once again and removed the 4WD housing. In doing so, I found some interesting bits inside. Sure enough, the 4WD engagement arm was
not connected to anything. As a bonus, it appears a (maybe "the") clunking sound was coming from within this housing.
For those who are considering removing this housing, be aware, removing the drive shaft lets loose two sets of ball bearings, one of each end of the shaft. It is best to have a bin at each end to catch them when they fall.
Also, the front shaft housing slides over the rear housing in order to expose the shaft for removal. This normally should go easily, except mine had a dent in it, which meant it would no longer fit over the small shaft housing. I ended up having to cut a slit into the dent and pry it out with a screwdriver. If I had a welder handy, I would likely have welded a bolt to it and used a slide hammer to pull the dent out. I don't have power in my garage yet (just built it), so that wasn't an option for me.
Getting the engagement arm off was a small nightmare. First, the roll pin was frozen in there, and drilling it out proved fruitless, as the pin is apparently hardened steel. One drill bit down, I managed to finally drive the pin out with an old hex bit ground to be round. After removing the roll pin, I found the shaft itself was rusted to the handle, so round two commenced with me placing the handle in the vise and hammering the crap out of the pivot shaft. I immediately sanded the shaft smooth to avoid a similar scenario upon assembly.
The arm inside the housing, which normally moves the clutch dog has been bent pretty badly and is now getting jammed into the transmission gear. As a result, half of the knob is has been ground off.
Luckily, the clutch dog tumbling around in there only partially damaged a single tooth. It appears it will live to drive another day.
The clutch dog was a bit worse for wear from rumbling around in the housing for who knows who long. I'm seriously lucky it never jammed itself between two meshing gears, as that would have been catastrophic.
So, all in all, not too bad. In order to get the shaft pivot out I need to remove the gears in the housing, which requires destroying another oil seal, so that will be on order shortly. The pivot arm and the clutch dog will easily be repaired by adding some weld to them and grinding them back to proper dimensions. I may order a new clutch dog if it is cheap enough.
As it was, the tractor was impossible to shift into 4WD, even though the lever would move back and forth, simulating the shift. Which goes to show how shady the guy I bought it from was, as he claimed he tested the 4WD engagement earlier that day. Uh huh..
All in all, about what I expected. I'm happy to see the gear clunking sound may have been this section, as I
really don't want to have to dig into the main transmission or remove the axle yet again.