After the top cover is pulled, the gears can be inspected. They also look surprisingly good. The T-case has a worn rear bearing, which leads to leaky rear seal, so the oil level was very low when the truck arrived here. The concern was that the gear teeth would be worn or blued, but that's not the case.
After the rear bearing retainer is pulled, the rear race and bearing can be inspected. This wear is the source of the looseness in the t-case output shaft.
Other than the worn bearings, seals, idler shaft, the t-case guts look good. A proper rebuild with a complete rebuild kit is all that's needed.
Scraping 30 years of crusty schmutz off the t-case is time consuming, but it has to be done before the empty case even goes in the tank.
After washing in the solvent tank, it doesn't look bad.
The cleaned gears are stuffed back in the case, along with the new bearings & seals from the rebuild kit.
All closed up. It seems the layers of 90wt and dirt protected the outside of the T-case. After soaking in the carb stripper tank, all the bolts and small parts looked good also.
Mating to the transmission, after scraping piles of the same gunk off the outside of the H42.
Ready to mate w/ BH.
Getting close to reinstallation time.
Actually Jim will probably be retired by then, because there is nothing wrong with it. 
