I have a '95 3.0 with the A/T. I got the 2.85 t-case gears last year but I haven't had the money to put them in until now. The gear mechanic called me this morning and said that the gears won't fit. I'm wondering if I was sent the Gen I gears instead of the Gen II. I'll post some pics when I get home from work later.

For one of the gears, maybe called the idler gear or cluster gear I don't know the right name, the new gear is made to fit on a shaft but for the one in my case the shaft and the gear are all one piece.

Can anyone tell me from my description what my problem is?

-Kirk

I did my own Gen I. I have not been in my Gen II's case. I will have a look at my FSMs tonight and see if I can help at all.

In the mean time, do you know about the how the main shaft's gear (forget it's exat name, too) might not fit through the hole in the case? In which case you will need to assemble the gear/shaft in the case. And in order to get the last snap ring on after that is all said and done, you will need a ground down snap ring pliers.

Here's my thread from last year...

No idea.

here's a clue from your previous thread.


I have one of these and I thought the Gen II did not need one. So I guess that means I was sent the wrong gears. <img src="/forums/images/graemlins/frown.gif" alt="" />

Hey Frank, are you reading this? Do you know if there are any gears left for the Gen II 3.0 A/T?

-Kirk

Wait a minute, I've been thinking more about this.

The mechanic has dismantled the front of the t-case where the shifter is and is trying to match up the gears in there. Is this right for the Gen II? I thought the gears went in the rear part of the t-case with the chain. My Gen II manual does not have a diagram of the inside of the t-case so I can't verify it.

My gen I manual shows it this way but I know the Gen II is a little different.

Can anyone tell me?

-Kirk

i just got the snap ring in on mine... Once you get it right its quite easy! However getting to that point was a PITA!

The hub on mine did not fit well on to the shaft (both factory parts). Total bear getting the parts into the case when the splines wont fit.

It turns out that my splines fit well if indexed a certain way and in fact slid right on once I figured that out.

Once I got that down I was able to get the snap ring into place. Before seating the snap ring into place (it was close to the groove) I mounted the chain and the output shaft for the front axle.

Second go around would be much easyier. Just hope all those needle bearings are ok after a handfull of trial assemblies.

I call it the ship in a bottle transfer case.

Kevin

My Gen II FSM has no diagram either. (I need to get better ones!) I would think that they are fundamentally the same as the Gen I, Active-Track aside. Yes to their going in on the front. I think the only gears in the rear, with the chain, are the ones that engage the 4WD. The hi/lo are in the front.

In the gear/shaft/fit comment I first made, when the guts are taken out, if the case is front side down, the chain, it's gears, and the two shafts can all be pulled up and out from the case. But when the new gears are on, the whole thing won't (might not) go back in the same way. One of the new gears is slightly larger than the hole that they came out through.

What needs to be done instead is to assemble the chain, shafts, etc., and slide them back in while fitting the gears on in the process from the other side of the hole. at the end of it all is the snap ring that the only way to get it back on is with pliers that have been ground thin enough to fit in what little space is left.

Whoa, was just looking though some old pics... DON'T FORGET TO SHAVE THE SHIFT FORK that sits above the new gear. You should see a small grinding that is there from its fitment to the old gear. You may have to take a little more off. Be sure to test the shifting before calling the work done.

I added pics at the end of my old thread.

HTH

P.S. Interesting comment from Kevin on needing to index the gears. I don't remember that being the case with me. But mine was MT, so maybe there's something different there. We know the gears are different in some way.

Kirk,

I sent you a manual on the T-case. Hope it's better than what you have. The gears were developed on Mr. Bishi's 3.0L Gen II, so they should fit your's. The only differences listed in previous threads was that the manuals use a 24 spline input, while the auto's use a 23 spline. They should fit with no modifications what so ever (unlike the Gen I's).

Looks like Lee is right, the issues I outlined seem to be Gen I. Here's a thread from Outer Limits I also had going when I did mine.

<img src="/forums/images/graemlins/lol.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" /> good one!! I hope you guys get your gearboxes all buttoned up!

I have the answer now.

Lee, many thanks for the manual. Everything is clear now. I'm screwed.

The manual shows the Gen II t-case where the idler gear (also called the counter gear) has a shaft with needle bearings. However in my t-case the idler gear is all one piece, with ball bearings pressed on the end. Also the gears in my t-case are considerably larger than the new gears.

Can anyone explain what happened?
Do you suppose that the U.S. had a differnet t-case than the rest of the world?
Has anyone put the gears in a Gen II t-case yet? which idler gear did you have needle bearings with shaft or ball bearings?

-Kirk