Need help on Sunday with my splitcase toybox (1 Viewer)

[nailed]

I got through the assembly of the toybox to the stock 4 speed. I am ready to install transfer case. I machined the split case to clear the shift rail and bolted them together. The problem is the gears are not lining up in the split case. The spacer length is off about 11/16. Do I cut the long spacer for the back side of the gear and make a new one for the front or is this something that Marlin didn't ship??? Once I am past this it will be finally assembled. I have pictures of the assembly and answers to the questions that came up for me. I plan to post once finished. There isn't a lot on the full assembly of these things and I thought it would be good to get some more info out there.

 

[LCOwner]

There have been some variations noted in that distance from case to case. Don't cut the PTO gear spacer. How many spacers did Marlin ship? You may need to mix and match those spacers or worst case have them milled to the proper thickness it's OK to stack the spacers. The two gears should be flush.

 

[cruzila]

Yes the variations are in the input gear. there are several versions. The most basic being the 5 speed version and the short 4 speed version. you need the correct spacer combo and the gears will line up perfectly.

 

[nailed]

Thanks for the replys. I had to unexpectedly leave for the day and just got back. Marlin didn't send any spacers. Looks like a call tomorrow AM.