is this the gear you are talking about?


here's a pict of the front of the hi-lo assembly. behind it is the 4wd gear picture above. the two do not slide into each other but butt up against one another and the collar will slide back and forth to couple them together.



-Rob

I believe so - if you look at mine from the other side it has two inner diameters that create the "shelf", for lack of a better term. Its the depth of the larger inner diameter that was cut wrong.

Well I think I understand what is happening. The Tera four wheel drive gear is loose between the high-low clutch and the sleeve the needle bearing rides on.

The 60 ft-lb torque isn't what really presses everything on the correct depth. You still have to put a socket over the set of gears and tap it on until the 4wd gear has very little slack. Then put the nut on and torque it to the required 60 ft-lb spec.

I'd say if everything went in and shifted it should have worked. I'm guessing you had the correct gear, just not tightened up correctly.

Yes thats it exactly, almost! But not because its not tight enough. Even doing what you suggest the gear was loose. The gear has two inner diameters the larger of the two is cut to deep and causes the loosness and the noise. Predator measured it all w/ a micrometer and Tera said the depth of the larger inner diameter was way off spec. They also compared it to the original gear to confirm what Tera said. Tera wants the whole kit back so they can figure out what went wrong where. Sorry for the bad sketch before.

What's the good word here? Has Tera contacted you about them sending new gears out yet? What exactly was the problem?

I hope this isn't your daily driver??

Good news is I have my truck back and the Teras are in and working. Bad news is it cost me a little under twice what I was quoted because of all the taking out and putting in. Plus yes its my DD.

The gist of the problem is that the inner diameter of the transfer input gear was cut to big as well as the height of that same diameter was cut too short. Causing the gear to actually rattle. I will post a pic of what I am trying to say once I get home tonite.

I may try to make a case with Tera for shipping badly cut gears to one of their retailers to make up the extra install charges. Problem is I got them from Sams but Sams didnt install them , a Tera shop here in Colorado did. What do y'all think ? Should I even try?

You should definitely call them and tell them, they ate the majority of the cost when my install went awry. I wouldn't be rude, I'd prolly just mention it, especially since they even asked for the parts back to investigate....

Peter

This is why most shops like to buy the parts that they install. If that had been the case you wouldn't have paid an extra dime. It would have been between Your Install Shop and Tera.

Steve G

Well not exactly Steve. The shop is a top Tera shop, with plaques from Tera all over the walls and they told me that they could've easily been shipped the same faulty part as Sams and I would've been charged the extra labor amount anyways. I was told that they have never been compensated for labor from Tera, just parts and that I would have a hard time asking to recoup my labor charges. I would hope that I would get a break since the part was definitely cut wrong and needed replacement. But who knows, apparently theres still some tension at Tera over producing these kits for Isuzus because of lack of sales.

If a shop quotes a price for a job, I think they are obligated to stick to the price quoted. If a job goes smooth and takes them less time, do they offer to charge you less? I think not. And if a job take them longer, should they charge you more? I think not.

Case in point: My Tera Low install took about twice as much time as estimated. John, orignally had the bill for exactly what he quoted. I basically forced him to split the difference with me and I paid a couple extra hours of lavbor to him for his trouble.

His offer to charge me as quoted left me with a very good feeling and I hope my paying extra will give him a good feeling the next time I use his services. I didn't want him to cringe everytime he sees my Amigo driving into his shop.

I refered another guy to his shop but John declinded to do the work for him because he had bought his own parts. I had also bought my own parts but because I have done plenty of business with him ove the years, he did mine anyway.

This fellow is also a well know Tera Installer. All 4 Wheel Drive in Corona, CA.

Steve G