First time rebuilding a transfer case

[B1oodyBuzzard]

Only thing holding me up from reassembling now is scrubbing the case and make it look pretty

 

[B1oodyBuzzard]

I used a write up in the FAQ. Very detailed. Freezer, oven/torch and press are your friends.

Started reading through the FAQ last night. I’m usually scrolling the classifieds and forgot about how amazing the FAQ section is. Thanks for reminding me.

 

[B1oodyBuzzard]

Any leads on like new gold output cone cover?

If I get it cleaned up enough I may want a shiny one just because.

 

[B1oodyBuzzard]

realized I screwed up the moment I slid the speedo gear on.

 

[B1oodyBuzzard]

Feels like It’s taken forever but I have the transmission&Tcase back in the vehicle and I’m trying to finish it up BUT I have a new issue.

i torqued the transmission output nut to 90ftlb, tcase front output nut to 90ftlbs, and the drum brake to 90ftlbs. I noticed the front output does not turn. I broke the output nut loose and it moves slightly with the brake even tho the shift position is in 2high. Transfer ccase is also not shifting from 2H to 4H.

Any guesses what I screwed up? Any suggestions?

I really don’t want to pull her out or buy another seal kit.

 

[POPO AGIE]

Make sure that thrust washer is lined up with the pin in the output shaft. Otherwise it will take up all the clearance and lock up the transmission.

 

[B1oodyBuzzard]

I was wondering about the preload. There was a shim that I reused. Maybe I should’ve left it out?

Make sure that thrust washer is lined up with the pin in the output shaft. Otherwise it will take up all the clearance and lock up the transmission.

Everything turned okay until I mated the trans and tcase and torqued it down. I guess I’m just procrastinating on pulling apart again…

 

[charliemeyer007]

That sounds like some bearing/seal located in-between the 2 units is a little proud, and doesn't bind until both units are torqued together

 

[POPO AGIE]

I was wondering about the preload. There was a shim that I reused. Maybe I should’ve left it out?

Everything turned okay until I mated the trans and tcase and torqued it down. I guess I’m just procrastinating on pulling apart again…

I fought with mine for a couple of days and that washer kept turning so the slot did not align with the pin. Then once I had it mated to the transfer case it was locked up again and was just one of the sincros was locked up and used a screw driver to get it back in the right place. Leave the shifter cover off until last.

 

[B1oodyBuzzard]

figured out I installed this selector fork backwards. Everything seems to be shifting properly now on the transfer case.

 

[charliemeyer007]

Good job. The devil's in the details. Taking good pic's and notes during disassembly helps when putting stuff back together.