Transfer case input and output shaft polishing

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

H

hisandhers80s

SILVER Star
Joined
Aug 17, 2025
Threads
21
Messages
309
Location
Madison, MS
I have been watching Georg's videos on the transfer case rebuild series, and he talks about polishing the input and output shafts. Does anyone know the best way to polish these without messing up any tolerances, etc.? I see online about emory cloth and 1000 grit sand paper, but I wanted to see what the Mud Wisdom has to say on this.
 
The shafts are soft, meaning they have not been heat treated. Anything other than soap will remove material, increasing the clearance between the shafts and flanges. I haven't seen the videos, so I don't know what you (or he) is referring to exactly, but if you're removing anything that isn't above the generated tooth profile, you're increasing design clearance. I'd ask him directly.

If you're referring to polishing the seal journals, go ahead. Just remember that anything you take off has to be made up by the seals. I wouldn't use anything harsher than lapping compound. If there's a gouge, you can fill it with epoxy and sand that to the original profile.
 
Malleus said:
The shafts are soft, meaning they have not been heat treated. Anything other than soap will remove material, increasing the clearance between the shafts and flanges. I haven't seen the videos, so I don't know what you (or he) is referring to exactly, but if you're removing anything that isn't above the generated tooth profile, you're increasing design clearance. I'd ask him directly.

If you're referring to polishing the seal journals, go ahead. Just remember that anything you take off has to be made up by the seals. I wouldn't use anything harsher than lapping compound. If there's a gouge, you can fill it with epoxy and sand that to the original profile.
Click to expand...

@orangefj45 can you shed some light here on what you were talking about in your videos with Timmy the Toolman?
 
Malleus said:
The shafts are soft, meaning they have not been heat treated. Anything other than soap will remove material, increasing the clearance between the shafts and flanges. I haven't seen the videos, so I don't know what you (or he) is referring to exactly, but if you're removing anything that isn't above the generated tooth profile, you're increasing design clearance. I'd ask him directly.

If you're referring to polishing the seal journals, go ahead. Just remember that anything you take off has to be made up by the seals. I wouldn't use anything harsher than lapping compound. If there's a gouge, you can fill it with epoxy and sand that to the original profile.
Click to expand...

The shafts are DEFINITELY hardened.

We polish them with a very fine grit Brillo pad. Been doing that for decades without issues.

Georg @ Valley Hybrids
 
hisandhers80s said:
I have been watching Georg's videos on the transfer case rebuild series, and he talks about polishing the input and output shafts. Does anyone know the best way to polish these without messing up any tolerances, etc.? I see online about emory cloth and 1000 grit sand paper, but I wanted to see what the Mud Wisdom has to say on this.
Click to expand...
Why not just reach out to us with this question since you’re referring to our videos?!

Georg @ Valley Hybrids
 
good to know.
 
hisandhers80s said:
Probably should have! Definitely will from now on!
Click to expand...
It’s why we put these videos together, to share information, support the community and obviously get some exposure and hopefully parts sales.

We’re happy to help.

Georg @ Valley Hybrids
 
You must log in or register to reply here.

Share this page

Back
Top Bottom