Talking to myself again - I guess t-case work is for loners. <img src="/forums/images/graemlins/lol.gif" alt="" />

I've found another FSM issue. The FSM and the OE parts list diagram call for the spacer (if needed) to be placed on the front output bearing, followed by the wave spring (if necessary) before installing the front cover that contains the pulse generator pickup sensor. My t-case had the spacer installed first (against the bearing) and then the wave spring. I don't know that it makes any difference, since the t-case functioned in 4WD, but I think I'll re-install it like I found it - even though it would seem to make more sense to have a wave spring working against steel rather than the aluminum cover recess.... surprisingly, observed wear on the 4 wave high points was minimal.

Also, the FSM calls out .078" as standard clearance between the bearing and the cover recess, with the spacer used if clearance is more than standard. I have considerably less than standard (.040"), yet a spacer was still installed, along with the wave spring. Allowing for the compressed thickness of the wave spring and the spacer, there's barely any clearance - maybe .001", but that is increased by the gasket thickness of .010", so I guess that's ok also.

Just wanted to put this on record in case anyone else runs into it.

Frank