Split case reassembly ???

[66fj40x2]

I had to replace a bend 4wd collar and rod and am tryin' to get the splitcase reassembled. I can get it to within .25 to .5 inches but it sure won't seat fully. This is the first time I've had to do this under the truck and it's prooving to be a PITA.... I'm sure I'm hanging up on the coller to the front output and I've greased the crap out of it to hold it place but still no luck .

I've got about 5 hours in this SOB right now and am getting purdy fed-up..... Anyone have any tips or tricks to make this go easier?

Thanks,
Mike

 

[Dynosoar]

Pics would help us diagnose the problem.


Dynosoar

 

[Toyrod]

Just put my 84 split case back together. The o-ring on the idler shaft was a firm fit and held it back about 1/2 inch. Keeping the back case square and even pressure took care of it. You should be able to engage the 4wd into the 4wd position and it will not interfere with the assembly. It will only be the pilot bearing from the output shaft into the front drive shaft (not driveline) that you need to line up. If you have the pilot bearing packed with grease, you could have it hydraulic'd. Meaning the grease is not compressing or squeezing out of the way. This will stop you also.

 

[66fj40x2]

Managed to get it back together a couple hours after posting. I've not bolted everything up yet.... It looks like the rear output is pushed back and I have a little gear oil dripping from the rear output now. Gonna take the rear cover off today and see whats up with that.