transfer output shaft wear

Joined
Jan 19, 2003
Messages
688
I am rebuilding my spare 3-speed transfer case. There is some
wear of the "dog teeth" on the high speed gear. The clutch
sleeve mates to these teeth and then onto the output shaft.
My question is: how much wear is too much? I can't find anything
in Haynes or the factory service manual to tell me what the wear
limits are. The movement is less than one degree of rotatation, and
the dog teeth are only worn on one edge. Sorry if the words don't
make sense -- I tried a photo but it did not turn out too well.
 

alf

Joined
Jan 30, 2003
Messages
717
Location
atlanta
When in doubt replace it. Have you checked the price of the replacement part? I hate not doing something right the first time and the kicking myself.


alf
 
Joined
Jan 19, 2003
Messages
688
Shaft + high speed gear + clutch sleeve = $420 new. That's too much.
Some wear is tolerable, the question is: how much? Since this is my
spare, I'll put it back together and see how tolerable it is. Then I
can tear my non-spare down and see how much wear it has!
 
Joined
Feb 6, 2002
Messages
15,332
Location
OC, CA
It is hard to tell what the wear limit is. The wear usually leads to them popping out of gear before the teeth will shear off. If the sides of the teeth are straight and parallel, they are usually OK. When they are worn on an angle to a point, then it tends to pop out of gear.

One trick is to flip the clutch sleeve over and use the newer surface. Also make sure that the bushing is good because if the gear is loose on the shaft they won't stay in gear.

Just put it together and keep your fingers crossed. It isn't that hard to remove and replace if if you have to.
 
Joined
Jan 19, 2003
Messages
688
Thanks PH. My wear is parallel to the tooth and is only on one shoulder.
Frankly I think its minor compared to some of the photos I've seen.

I do have a question (actually 2) about something that was posted earlier.

1. Aussie kits may not have a properly hardened idler shaft --
go OEM with this part. Agree? Disagree?

2. The bushing in the low speed gear tend to wear out. Why the
low speed gear? My cruiser is rarely in low. I replaced the bushing
on the high speed gear because this is the one that seemed to have
more wear.

here are my "teeth"
 
Joined
Feb 6, 2002
Messages
15,332
Location
OC, CA
[quote author=rgentry link=board=1;threadid=8909;start=msg77473#msg77473 date=1071784865]
Thanks PH. My wear is parallel to the tooth and is only on one shoulder.
Frankly I think its minor compared to some of the photos I've seen.

I do have a question (actually 2) about something that was posted earlier.

1. Aussie kits may not have a properly hardened idler shaft --
go OEM with this part. Agree? Disagree?

2. The bushing in the low speed gear tend to wear out. Why the
low speed gear? My cruiser is rarely in low. I replaced the bushing
on the high speed gear because this is the one that seemed to have
more wear.

here are my "teeth"
[/quote]


Teeth look fine and the bushing looks new.

I don't know that any of the idler shafts are great because I have never seen one that came out that was good enough to reuse. Some may be too hard because the surface is spalled.

The low gear bushing wears because it is always spinning on the shaft when it is in hi range. :doh:
 
Joined
Jan 19, 2003
Messages
688
>> Teeth look fine and the bushing looks new. <<

Bushing is BRAND NEW because I replaced it!

>> I don't know that any of the idler shafts are great because I have never seen one that came out that was good enough to reuse. Some may be too hard because the surface is spalled. <<

OK. I am using the Aussie kit. Will know in a few years. Frankly, I thought
the shaft that came out of the transfer looked pretty good.

>> The low gear bushing wears because it is always spinning on the shaft when it is in hi range. <<

You got me.
 

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