Installing Crawler gears, any advice?

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raydouble, ive read all that. I thought there might seem to be some MUD experience around here somewhere. Jerod, for some reason i though you had to grind the tcase housing itself, but i dont see that in marlins directions.
 
If you are installing 4.7's you do, maybe you missed that part... :D It's all very straight forward, I just printed out the MC directions, and took them with me to the shop. Line up everything that you take out so it goes back in in the same order.
 
It's not as hard as I thought it was gonna be. You just need to keep everything organized and labeled. Muffin trays for the small parts, string tags and sharpies for the bigger ones.

This is a great doc, print it and study:

http://www.marlincrawler.com/sites/all/marlin/files/docs/470-installer.pdf

You do need to grind the inside of the case, see step #56 and 57 on page 11, and step 62 on the next page. I used a new 4-1/2" disk in my grinder, I did it outside so I wouldn't fling aluminum shavings all over my nice clean workbench. I clamped the case part to a sawhorse, wore heavy gloves and goggles, and used compressed air to blow all the dust off the case afterwards. There's also a tiny bit of grinding on one of the shift forks, step 49. It will be apparent as you go along.

I think this doc was written with a top-shift case in mind, a few things were out of order, and they forgot to tell you to install a big snap ring on the center bearing on step 47. There was also something messed up in the order of the main case assembly, but I got it figured out easily. I did not use the gaskets provided in the gearset, I ordered an OEM gasket set, they are higher quality and fit nicely.

Heyyy... wait a second... I THOUGHT YOU HAD TO PAY FOR SCHOOL??? tsk tsk tsk... didn't listen to our advice, huh? :)
 
here is one,
do not drive the roll pin all the way into the shift fork that you grind down....

you ground it down for a reason, you don't want the pin sticking out on that side!!!!!!!!!!!
or put it in and grind both at the same time.


leave out the inter lock pin if you are going twin stick.

you can leave it out and just use the regular shifter but it feels really loose and you have to re learn how to shift it.
 
I was always intimidated at the thought of taking a TC apart. Shoot, there was a time when I was intimidated at the thought of just removing a TC from the tranny. Having now rebuilt one and installed two I can say I really had nothing to worry about. Super easy. My FJ60 case was way more complicated than the gear-drive mini. Just read the directions, don't read anything into them, and don't over analyse the rebuild. It is very straight forward. The factory service manual helps.
 
Yup, I've rebuilt quite a few Cruiser split cases, and I'd MUCH rather do a mini-truck case now. Much easier. It's also nice to be able to work on it sitting on a bench instead of under the truck.
 
I have a buddy that's a mechanic at the local dealer ... recently promoted to foreman of the shop. When I put my dual case/R151 together to told me to loose the paper gaskets and use Toyota FIPG or RTV.
 
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