Re-installing the speed sensor

[glinskonian]

I had my transfer case out recently, and upon trying to re-install the speed sensor, I could not get it all the way inserted. It looks like the plastic gear on the sensor side won't mesh with the worm gear in the transfer case.

I tried the obvious - rotate the flange and therefore the worm gear to line them up, but it refused to mesh.

Does anyone have ideas or tricks to get this thing to go in? Is there a specific orientation that the speed sensor gear needs to be aligned with the gear on the transfer case?
It's driving me crazy!

 

[Kernal]

Are you refering to the speedometer shaft assembly that holds the shaft with the plastic gear?

IME it slides in without any issues other than maybe a little wiggle/rotation of the shaft assembly.

Can you post up a photo of the speedometer shaft assembly/housing and another photo looking into port for the shaft assembly showing the worm gear?

 

[glinskonian]

Are you refering to the speedometer shaft assembly that holds the shaft with the plastic gear?

IME it slides in without any issues other than maybe a little wiggle/rotation of the shaft assembly.

Can you post up a photo of the speedometer shaft assembly/housing and another photo looking into port for the shaft assembly showing the worm gear?

Yes that’s the one. Both the speedo and the transfer case haven’t changed, so I know it’s not related to a wrong part.

I’ll post up some pics tomorrow when I’m by the rig. Appreciate it.

 

[glinskonian]

Are you refering to the speedometer shaft assembly that holds the shaft with the plastic gear?

IME it slides in without any issues other than maybe a little wiggle/rotation of the shaft assembly.

Can you post up a photo of the speedometer shaft assembly/housing and another photo looking into port for the shaft assembly showing the worm gear?

Here's some pics

 

[Kernal]

Have you tried removing the speed sensor/sender from the speedometer shaft (housing) assembly, then inserting just the shaft housing (with the shaft/gear)?
Does the shaft gear rotate freely in the housing (before installation)?

Do you see the worm gear move when you turn the Rear output flange (both driveshafts removed, transfer case in gear?)?

Did you replace the shaft oil seal and the O-ring for the assembly/housing while you're in there?

You can put some grease on the gear teeth before sliding it in (to provide some lubrication on start up), or squirt a bit of gear oil onto the worm gear and the shaft gear.

 

[glinskonian]

Have you tried removing the speed sensor/sender from the speedometer shaft (housing) assembly, then inserting just the shaft housing (with the shaft/gear)?
Does the shaft gear rotate freely in the housing (before installation)?

Do you see the worm gear move when you turn the Rear output flange (both driveshafts removed, transfer case in gear?)?

Did you replace the shaft oil seal and the O-ring for the assembly/housing while you're in there?

You can put some grease on the gear teeth before sliding it in (to provide some lubrication on start up), or squirt a bit of gear oil onto the worm gear and the shaft gear.

I got it! I removed the shaft first like you said to sanity check everything and as expected it meshed fine. The fit is quite loose actually so I think it was engaging the whole time.

I ended up oiling the worm gear and sensor shaft generously, and with a little force, it popped in.

Appreciate your help.