Transfercase woes part 2

[BigSur]

Ok, i pulled the rear bearing retainer...its ok and then i pulled my rear t-case cover and took some pics of the rear output shaft assembly area. Now from just looking at the pictures can you tell if the assembly is seated correctly?

Now were the rear t-case cover cracked, i know the route of the cause is in the rear assembly area. Looking at things it makes me think that everything is ok but i am no expert and can't tell. For those of you who have rebuilt your t-case does the rear assembly look ok?

Thanks Guys

 

[Aseif007]

Shouldn't the gears be flush if not almost flush in these two areas? It has been a little while, is the shifter linkage in correctly?

 

[Mace]

In the second pic, the two egars that mesh should allign perfectly,. There appears to be a 1/8" difference

Aseif has it right.

You pull off the front bearing protector?

 

[Dynosoar]

The gear stacks apper to out of alignment. Idler gear looks to be sitting aprox. 1/4" deeper than the output gear. By the looks of it 1. Your thust washers are not in properly, or 2. your ouputshaft is not seated into the front bearing properly. I am not a pro mechanic but I have had my t case apart several times and never had any reassembly problems.

Dynosoar

 

[Dynosoar]

Yea, what they said!!! I just type to slow.

Dynosoar

 

[BigSur]

Mace i didn't take off the front bearing retainer. I didn't need to replace anything on the front end cause i had done it previously.

I guess there lies my problem? Suggestions?

When i am lining up the gears should all the gears in the t-case be lined up perfectly?

 

[BigSur]

BTW thanks guys...this was my first major rebuild of some big on the truck and so i am still learning. Although i just wish this lesson learned wouldn't of cost me my t-case cover.

 

[Cruiserdrew]

Is the thrust washer behind the idler gear?

Is the front race retainer fully seated in the case?

As others have said, those gears should align, though a missing thrust washer would not cause the case to seat improperly and crack, the gears just would not mesh right. I'll be interested to hear the solution.

Are you doing all of this work under the truck?

 

[BigSur]

What's preventing my rear output assembly to seat correctly?

 

[Cruiserdrew]

It looks in both your pictures that the race retainer for the front bearing output shaft is not seated properly in the front half of the case. Normally the retainer sits flat, yours sits out 1/8 inch or a bit more. That almost has to be the problem and if not corrected will crack any subsequent case half you bolt in there. Pull off the output shaft and look very carefully at the big round thing that holds the front bearing race. It has two small ears that fit down in a notch. It should end up flush with the inside of the case.