It was the first time I had ever seen the t-case open and I probably miss-spoke about the neighboring gear. Whatever the piece is called that is supposed to sit flush atop the new gear. I hit my head pretty hard last nite so I am even confusing myself today. <img src="/forums/images/graemlins/shiner.gif" alt="" />

I'm with Rob on this one. IIRC, the 4wd gear is the only one that they could be refering to and it does not sit flush to the cluster behind it. There is a synchro inbetween them ect. Kind of strange, as this particular problem has not been heard of before.

It really does not matter, as it is being taken care of and in the end they will send you out the door with it working properly.

Good Luck,
Michael

By flush I mean to the shelf inside the inner diameter. Damn I shoulda taken some pics while I was there. I know you guys know this better than I do, thats why I like the Wire. I am just having a hard time explaining anything today to anybody. As for never seeing this b4, thats what Tera said too. I'm betting its just a one off anomoly from their gear cutters, just my luck. The height of the shelf didnt match anything that Tera has in stock for the 307L-A kits. Hence whole new kit tomorrow. Maybe I can get a pic of the bad part and make more sense later.

Thanks to everyone !!!!

this same thing happened with another set of gears i installed in a trooper.

what did? Troy, if you're familar with this, can you explain the problem to myself and Michael just for kicks? I'm not sure I follow what exact is wrong about the 4wd gear?

-Rob

IÆm not sure, but this might help to clarify things a bità

I could be wrong (and I donÆt know the correct terminology), but the way that I read it, it sounds to me like the æpeakÆ and ævalleyÆ sections of the teeth on the 4x gear - and its smaller counterpart on the idler - are not meshing together correctly, and that this is due to one of them having either too much æpeakÆ or not enough ævalleyÆ.


Cheers! <img src="/forums/images/graemlins/cheers.gif" alt="" />
Smiley

Ok did a little research in hopes of clearing up the confusion for posterity - Hope I got it right.

The high-low clutch hub sits on the transfer input gear, actually on a shelf cut into the input shaft. There is also a shelf cut into the inner diameter of the transfer input gear that the clutch hub sits in, not on. This shelf should essentially match the shelf cut into the shaft when the gear is placed on the shaft. The depth of the gear shelf was cut to deep to match the shelf on the shaft therefore there is play between the clutch hub and the input gear and thus the subsequent noise/tick/rattle.

Dale

Thank you for the more detailed explanation, though forgive me if i'm still just as confused. <img src="/forums/images/graemlins/confused.gif" alt="" />

I'm not exactly sure about the "shelfs" you are speaking of. The input shaft is the same diameter all the way back except at the very tip where a bearing rides. where the hi-low assembly and the 4wd gear ride, there are no "shelfs" (if we're talking about the same thing).

IIRC, the 4wd gear (gear tera sends you) rides on top of a small needle bearing at the back of the tcase. the hi-low assembly fits right up in front of that, but rides directly on the splined portion of the shaft. when you shift into low range, the collar over the hi-low assembly slides to grab the teeth on the tera4wd gear and essentally lock it to spinning with the shaft.

are you saying the inner ID of the 4wd gear was machined too large? or are you talking about the teeth on the 4wd gear that engage with the hi-low assembly aren't meshing with the hi-lo clutch as tight as they should be?

-Rob

Yep <img src="/forums/images/graemlins/ignore.gif" alt="" />

Heres a very rough sketch from my bad memory



Dont know why the pic doesnt show ? BMP vs. JPEG AHAAA !

The shaft shelf I mentioned might actually be the top of the bearing collar ??