DrCharles
Full Access Member
My transfer case rebuild is driving me nuts!! I just went through it and replaced all bearings, seals and shift fork pads. I'd gotten the 2WD/4WD dog collar backwards too, so 4WD wouldn't engage. Took it apart again and fixed that. Everything working fine on the bench.
So I bolted the tailshaft on - and the input and output shafts are bound up together so tight that I can't turn the input and output separately by hand in N, and in 4L I can't turn any shaft either (since input and output want to turn together, but are supposed to be going through the planetary reduction).
I removed the tailshaft housing and now I can turn the input separate from the output, although it's "stiff" (not spline engagement, just friction). The only thing the tailshaft does is guarantee the output ball bearing stays in place, since IIRC there is a lip in the case, maybe a snap ring too so it can't go any further into the case.
WHAT can be so tight that the pressure against the output bearing race is causing the input and output to bind together?? The only thing I can think of is the new bronze I/O shaft bushing is too tall and it's taking up all the clearance plus a few thousandths. Please let me know ASAP if you've seen this and what to do about it! I don't dare "run it until it wears in"... and fill my case with bronze glitter....
thanks
Charles
So I bolted the tailshaft on - and the input and output shafts are bound up together so tight that I can't turn the input and output separately by hand in N, and in 4L I can't turn any shaft either (since input and output want to turn together, but are supposed to be going through the planetary reduction).
I removed the tailshaft housing and now I can turn the input separate from the output, although it's "stiff" (not spline engagement, just friction). The only thing the tailshaft does is guarantee the output ball bearing stays in place, since IIRC there is a lip in the case, maybe a snap ring too so it can't go any further into the case.
WHAT can be so tight that the pressure against the output bearing race is causing the input and output to bind together?? The only thing I can think of is the new bronze I/O shaft bushing is too tall and it's taking up all the clearance plus a few thousandths. Please let me know ASAP if you've seen this and what to do about it! I don't dare "run it until it wears in"... and fill my case with bronze glitter....
thanks
Charles