I just completed my dual T-case setup using a couple of 1980's gear driven T-cases. I got no instructions with the adapter plates on how to put them together, but I think I got it right. They both have brand new synthetic 75W90 gear oil, and I slightly over filled them.

I can hardly touch the shifter with my bare hand, and the whole cab gets extremely hot inside after only about 5 miles out on the highway. I cannot touch the T-case housing. I drove it for about 60 miles and it didn't explode, but I didn't like the extreme heat. I know they're supposed to get hot, but this is excessive.

I didn't open the T-case in the back, but the bearings and gears on the front one looked half decent. The one in the back get much hotter than the one in front, and even the tranny shifter feels hotter than what it should be - I guess the heat dissipates forward. I realize the bearings and gears are 25 years old and who knows how long these things sat before I installed them. I'd hate to redo everything again, but if that's what I have to do, then that's what I'll do. Any suggestions? Thanks