Let's play a game......

[Lost]

busted tcase

dude, i am easily able to relate to your situation. it SUCKs. something gave in my t-case 4 weeks ago. both front and rear output bearings are done, seals too. as well my rear diff bearing(s) are shot. it drives but is making a horible sound, the whole drive shaft wobbles, i get bad vibes at various speeds... while driving (too much offroading?) ive been broke lately and i theres no way i can afford this get this done at a shop.

i saved up for a tcase and rear axle rebuild kits from cruiser outfitters. they came in today
a buddy of mine is selling me a rear diff for cheap and let me do the rebuild in his shop (hopefully )
and a very kind friend of mine is giving a tcase for free!/if i help him rebuild a front axle. just got to go pick it up :S. we have no idea what shape the case its in but with the two i will for sure be on my way soon.
i printed the transfer chapter of the fsm and have some tools

your story/thread has given me the motivation do get this done since i have'nt been looking forward to doing this job. hijack over


i do have a question(to anyone), how fastened/tight are the gears to the shaft(s)?

 

[GLTHFJ60]

Mine's a 34mm.... sorry... I just bought the bolt and little hold-down flange from my dealer 2 months ago...

DAMN!! I'll have to ask Kevin if he has 38mm junk.

Thanks Mark!

dude, i am easily able to relate to your situation. it SUCKs. something gave in my t-case 4 weeks ago. both front and rear output bearings are done, seals too. as well my rear diff bearing(s) are shot. it drives but is making a horible sound, the whole drive shaft wobbles, i get bad vibes at various speeds... while driving (too much offroading?) ive been broke lately and i theres no way i can afford this get this done at a shop.

i saved up for a tcase and rear axle rebuild kits from cruiser outfitters. they came in today
a buddy of mine is selling me a rear diff for cheap and let me do the rebuild in his shop (hopefully )
and a very kind friend of mine is giving a tcase for free!/if i help him rebuild a front axle. just got to go pick it up :S. we have no idea what shape the case its in but with the two i will for sure be on my way soon.
i printed the transfer chapter of the fsm and have some tools

your story/thread has given me the motivation do get this done since i have'nt been looking forward to doing this job. hijack over


i do have a question(to anyone), how fastened/tight are the gears to the shaft(s)?

Yeah, pretty much the same story with me. First 3 hard wheeling trips that the truck has ever been on were this summer behind my heavy foot, and I guess the T-case had enough. Oh well!

 

[GLTHFJ60]

Alrighty, got the gaskets ordered from the dealership. The parts will arrive by Wednesday, so I should have it buttoned up by then. I'm excited!!

As soon as I can drive it, I'll come over and drop off your impact wrench Kevin. Thanks to everyone!

 

[GLTHFJ60]

FYI, these parts are listed for 4/85 - 8-87 according to my parts guy in Rochester, so I ordered them.

Gaskets:
36144-60020 $ 2.31 PTO cover
36143-60020 $ 8.60 Main case gasket (very important)
36152-60030 $ 2.57 Rear output shaft housing
36142-60030 $ 4.40 Tranny output shaft cover
90430-18008 $ 1.06 Drain/fill plugs (need 2)

O-rings:
90301-34004 $ 1.66 Idler shaft ends (need 2)

Nuts:
90179-22005 $ 3.94 Output flange stake nuts (need 2)
90179-26004 $ 2.74 Tranny output shaft stake nut

Other:
36222-60020 $17.98 Idler shaft thrust washer (need 2)

 

[Lost]

Yeah, pretty much the same story with me. First 3 hard wheeling trips that the truck has ever been on were this summer behind my heavy foot, and I guess the T-case had enough. Oh well!

mines been taking apart and put back together did it outside too
turns out there was a seized ujoint in the front. tomorow i swap my rear diff and put new bearings in the rear axle.

 

[GLTHFJ60]

mines been taking apart and put back together did it outside too
turns out there was a seized ujoint in the front. tomorow i swap my rear diff and put new bearings in the rear axle.

Good to hear that you already put yours together! Mine's been sitting, disassembled, in my fraternity parking lot for a month now. Awesome, eh?

Did you figure out the problem with your companion flange nut?

 

[kevinmrowland]

As soon as I can drive it, I'll come over and drop off your impact wrench Kevin. Thanks to everyone!

Sounds like a plan, I broke into your truck while you were gone and stole some stuff for ransom, so I'll get those to you when you bring back the impact.

(haven't needed it yet)

 

[GLTHFJ60]

Haha, nice. How'd you like my pile of t-case parts sitting on top of my rusty old skidplate?

I'm glad no one else broke into it since it's been sitting there.

 

[lehiguy]

Not really a good idea, you could use RTV for the PTO cover and the rear transmission output bearing seal, but the other gaskets are in tolerance sensitive locations, you could use RTV on the rear output, but you would need to make sure your bearing pre-load was still correct and if you used RTV on the case it would throw off not only the rear output pre-load but the thrust washer clearance as well.
The OE gaskets are high quality and seal very well, I recommend sticking with them.
[/quote]

That goes without saying. Bearing preload will always change with new bearings so you have to set it anyway. Many gear boxes specify RTV because it provides a superior seal. Make your own decision, but RTV is mine, it's at every retail outlet in the world and it never leaks. This isn't rocket science folks.

 

[GLTHFJ60]

Alrighty guys, it's done. I didn't check the bearing preload and whoever last touched the case stripped the fill plug, but it's together and driving. I took a chance and didn't wait till I could get it to a garage so I rebuilt it in the parking lot behind my fraternity house. Rochester gets pretty cold, but I finished it by 6pm and took it for a spin. The bearings are incredibly loud, but when I fill the case up all the way I'm sure some of that noise will go away. I could barely get the gear oil up out of the jug, it was so cold.

Anyway, I could title this thread "The $80 T-Case Rebuild" but I would not recommend anyone doing this other than in extenuating circumstances. Either way, it feels damn good to have it finished.

Has anyone got ridiculous stories of working on their truck in a parking lot?

 

[GLTHFJ60]

Alrighty, I'm an idiot. I neglected to install the bearing race for the output shaft, so I have to pull it apart again. It wasn't mentioned it in the FSM but it popped out during disassembly, so the part did not make it back in. Oh well, at least I'm learning.

 

[RockDoc]

Has anyone got ridiculous stories of working on their truck in a parking lot?

I swapped out my AT's valve body in a parking lot. But don't tell anyone.