Well ... Kudos to Chad for his help in dismantling the various T-Case parts (I personally was very worried about buggering things up) ...

Tonight I took the various parts to JR of MS Conception Motorsports who helped me put it all back together ... I brought the completed t-case back home and re-installed it ... fingers are crossed while the silicone dries ... hopefully the output shaft Randy sent will be the ticket !!

After installing the t-case I re-installed the driveshaft and found that one axis of the rear u-joint was binding VERY badly ... not sure if this had anything to do with the failure but ... :eh?: ... something else to replace (yay - new parts!!) ... should I replace the front u-joint at the same time (it has no signs of binding at this point)?

I also looked more closely at the right (passenger) side CV axle ... grease everywhere !! I'm thinking now that I "might" have done a "bit" more damage to the axle than just detonating the hub ... (still waiting on my "lifetime" replacement hubs from SW ...). I'll wait until I receive the hubs before investigating further, but ... it doesn't look good ... BOY am I happy that I made it home !! Good 'ol ZU !! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Pics have been developed, but now my motherboard is failing and I can't scan them in <img src="/forums/images/graemlins/angry.gif" alt="" /> (sorry Mike) ... these things come in threes right ?? ... I'm just wondering when that last shoe's going to drop ... <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

OK Mike ... before you get TOO involved in that Tera Low install (BTW send me your notes when your done <img src="/forums/images/graemlins/wink.gif" alt="" /> ) ... a couple of pics of my broken t-case output shaft can be found here (hopefully) ... web page

I'm VERY new at web-page building (NTM posting pics) so bear with me if this doesn't work...

Shortly (hopefully this weekend) I'll be posting pics of my "bound" driveshaft u-joint (correct term?), my replacement hub and my right (passenger) side CV axle (I'm VERY curious about what EXACTLY happened to this one ...)

Thanks all!!

[color:"yellow"] WHOOOO HOOOO!!! [/color]

I apologize for the loss of decorum ...


ahem...


Oil in the t-case ... buggared driveshaft installed ... Rodeo starts and ROLLS ... <img src="/forums/images/graemlins/smile.gif" alt="" /> <img src="/forums/images/graemlins/smile.gif" alt="" />


I can't tell you how HAPPY I am <img src="/forums/images/graemlins/kewl.gif" alt="" /> <img src="/forums/images/graemlins/kewl.gif" alt="" />.


Tomorrow I'm hoping to take care of the driveshaft and at least look at the CV axle ... Monday, those hubs had better be here ... I need to WHEEL!!

Thanks all,

Was is it now? Zero wheel drive to Rear wheel drive in a matter of hours? It's a beautiful thing, ain't it?

*sniff*

I love a happy ending! <img src="/forums/images/graemlins/smile.gif" alt="" />

Congrats! Not everyone can break a transfer case, win awards and a raffle, and come out the other side with lower gears and a repair! <img src="/forums/images/graemlins/kewl.gif" alt="" />

Randii

And the repairs just keep on comin ... I had no idea I did this much damage while I was in Moab ...

Took the driveshaft into GRS here in Salt Lake to have the u-joints replaced, and found that the shaft had been bent - nearly to the point where it couldn't be straightened. GRS was able to straighten it, but this could have been a contributing factor (along with the bound up u-joint) in the t-case output shaft failure. Funny thing is I *never* felt any vibrations under acceleration ...

Still waiting on the hub from SW so I decided to change the oil & filter, rotate the tires and clean the air filter. With the fron't end in the air while rotating the tires I took some time to clean a portion of the grease splatter from the passenger side CV - from outward appearnces it looks like the boot just split (some good news).

However when I put the wheel on I noticed a *significant* amount of slop in the steering (about 1"). I looked underneath while pushing / pulling on the wheels and saw movement in just about every joint between the pitman arm, centerlink and idler arm <img src="/forums/images/graemlins/barf.gif" alt="" />.

How do I start isolating which components I may have to replace to get this in running order again?

(FWIW I did mention to Ms Ramie that with the cost of replacing the CV axle and all steering components I might as well just go SAS ... no dice ... <img src="/forums/images/graemlins/frown.gif" alt="" />)

DOH!, man do I wish to see and help get one of these done before I ever venture into this. The Mrs' said that I can't do any major upgrading until it is paid off, so I guess I have a year. Glad it is better then before, Jim let me know if you need help, I would love to help if/how I can, even if that is taking pics! <img src="/forums/images/graemlins/smile.gif" alt="" />

Start at the Idler arm. Replace the entire assembly, the spindle is the usual problem, not the arm itself. Seems to be the weak link and makes the entire system look bad.
BTW I have just the arm (brand new) sitting in the garage if you need one, but I'd guess it's the spindle.

Next I'd do the passanger Tie-rod or both and lastly the center link if the above didn't fix it.

Seriously doubt your pitman is bad but later down the road if you discover it is, I have a brand new one sitting in the garage needing a home <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> (turns out mine wasn't bad )

Thanks Desha - I did some searching this afternoon and found this . Sounds familiar doesn't it?? <img src="/forums/images/graemlins/drunk.gif" alt="" />

I appreciate the info and the offer <img src="/forums/images/graemlins/kewl.gif" alt="" /> - I'll let you know. I've never messed with steering before (other than with the bodylift) - but (previously) I had never messed with my t-case either <img src="/forums/images/graemlins/rolleyes.gif" alt="" /> Another learning experience Please check back - I may have more questions for you.

PS - Did you get that letter?

Best regards,

Jim (lead foot) it will be nice for ya to come wheelin with us again. lol How is that ticket coming? Anyways good luck, and hope to see ya soon.

kevan <img src="/forums/images/graemlins/kewl.gif" alt="" />