This input gear doesn’t look right (1 Viewer)

[unfortunately]

Tearing open my transfer case today for a rebuild and I find this:

Now I haven’t been inside of one of these before, but something tells me this isn’t how the input and drive gear are supposed to look. Also that weld looks pretty broken to me, but I’m no expert.

Thoughts? What’s the prognosis?

 

[unfortunately]

Confirmed

 

[Travis 76]

Wow. Never seen that before.
Maybe the transmission output shaft wore out and this was the idea of how to keep using it. Get the fresh splines with the pto gear

 

[Dynosoar]

Someone made a homemade Mcnamara gear, and did not weld it very well.
Dyno

 

[cwwfj60]

Agreed with @Dynosoar

They were attempting to eliminate the clunking that comes from worn out parts on the output shaft splines. Unfortunately they were unsuccessful.

Were you experiencing any issues? Why rebuild?

 

[unfortunately]

Rebuilding because while doing the clutch i found the input shaft was toast. Looks like the bearing froze in place and started wearing away the metal. Since pulling the input shaft requires disassembling the transfer case, figured this was a good time to rebuild. You’re all right about what was going on in there, and thankfully a real McNamara gear magically appeared and I’m hopefully back in business.

 

[unfortunately]

The center piece that was welded in also had splines, in case anyone was wondering

 

[unfortunately]

And the splines at the rear of the shaft look less than stellar. The McNamara gear should take care of that in a more durable fashion, I’d imagine.

 

[cruisermatt]

Yep you’ll be good for another 20 years

 

[Skniper]

Interesting second look at a homemade Mcnamara gear from 'back in the day'. Wonder how well the rest of the homemades are holding up?

 

[Spook50]

Yeah your first post was a DIY McNamara gear. Weld looked okay, but I'm betting it cooled too fast and weakened. To do it the right way you need to clean it well, put it on a jig (Georg @orangefj45 uses a repurposed tranny output shaft to keep the splines aligned), weld it and then wrap it in weld blankets so it can cool slowly and not get brittle. Had the PO done it right that weld wouldn't have broken. But now that you've got a real McNamara gear and are doing a rebuild, you're good to go.

 

[tmxmotorsports]

I have done the same on my 62 been little over 2 years if i had to do over i would have just bought the gear.

 

[Skniper]

Part of the problem was that the McNamara gear used to be pretty damn expensive or hard to get. Georg supplies these now at a reasonable cost.

 

[unfortunately]

In all fairness, that gear did not just magically appear. Josh at Willamette Blvd Service Center here in Portland, Oregon once again saved my skin. He is a saint.

 

[island45]

I finally found some solid info. Is there a Macnamara gear for 16 splines out there? Thanks in advance. Or how to reach George if he still makes them. I guess I didn't invent this thing.....