Tranfer case rebuild help (1 Viewer)

[Cruising Canuck]

So I've torn apart a transfer case and I've come across what looks like a spun bearing

That journal bearing is supposed to be inside a big gear, but was stuck to the shaft when I pressed the gear off. It should look like this gear below.

So I've got a question, can I pull the main shaft out of a junk transfer case and put it in this one? Will there be any issues with gears meshing from different cases.
Basically Frankenstein one case out of 2 cases

Or should I get this shaft repaired somehow and keep all the pieces from one box together

 

[Mark W]

A good undamaged shaft will swap in no problem. The teeth and splines on the shaft are not gear teeth so there is no concerns about differing wear patterns causing noise.

Mark...

 

[Cruising Canuck]

Thanks Mark, but I am going to use the entire mainshaft and gears out of the other case, not just the shaft. That's why I'm curious about gear meshing

 

[Berry]

Are you certain that is a bearing journal and not the spacer from the rear output shaft? Regardless, wow that thing is worn.

 

[Mark W]

Thanks Mark, but I am going to use the entire mainshaft and gears out of the other case, not just the shaft. That's why I'm curious about gear meshing

You may have a bit more noise between the gears unless you swap all the other gears too. By\ut you might not, and I doubt that it will be significant anyway.

FWIW, you might try taking a wire cup brush on an angle grinder to that shaft and see how it cleans up. In the picture the surface appears discolored only and does not to my eye seem to be heat damaged. Since the brass will suffer before the steel, it may have done it's job and sacrificed itself , saving the shaft.

Mark...

 

[cruisermatt]

No reason to repair a output shaft when they are readily available new, OEM, inexpensively. I should have several in stock.

 

[cruiserpilot]

Hey Gary, should be no problem using any gears or shafts from other transfer case. Just has to be manual transmission case. Auto cases have a different gear ratio and I’m not sure where that occurs.
You got a full new bearing and seal kit?
If you do need parts not in kit let me know I might have what you need in the shed.
PM me and I’ll send my phone number. Can talk you thru anything if you need help.

 

[cruiserpilot]

Here are all your questions answered. Most valuable thread there is for transmissions and transfer cases.

some h55f and split case tech

forum.ih8mud.com

 

[Cruising Canuck]

Here are all your questions answered. Most valuable thread there is for transmissions and transfer cases.

some h55f and split case tech

forum.ih8mud.com

Thanks Jonathan! I will go through this thread tonight

 

[Cruising Canuck]

Next question for the community.
I have 2 t-cases. The one I'm rebuilding and a damaged one I'm taking parts from for this rebuild.
So I took apart my old damaged t-case and swapped the output shaft into the case I'm rebuilding.
Anyways I personally installed these bearings into the damaged case about 100 000km ago. Or 60000miles

The bearings and races in the damaged case have a pretty severe wear that I've never seen on a bearing.
They are heavily scored, I can actually feel the grooves with my finger nail.
I rebuilt this case and thought i did everything with care and correctly.
What the heck would cause bearing wear like this?

 

[cruiserpilot]

I don't have the experience for an answer, just don't know.
@orangefj45 Perhaps you can help us out here, Thanks.

 

[OSS]

The gear oil in the transfer case got contaminated with metal grinding off of something else. The oil became a grinding paste- and there you go.

 

[orangefj45]

I would tear that case all the way down and run it through the wash, and then inspect everything really well. Obviously, a hardened piece of steel got into the bearing to cause that type of damage. You should see distinct, wear marks, or breakage on the component that failed.

Also, I would not advise mix-matching the gears unless it’s an emergency. They tend to run very noisy. And there are different gear ratios, and tooth counts for different years of these cases.

Georg @ Valley Hybrids @ Cruiser Brothers